Building the Scar-H:

Here's a quick guide to building the SCAR-H. This process can be used to make any type of gun body.

I create a stencil by printing out a good, side on picture, you will need to find the length of the gun and print the picture so that it's the same length. I then create a CAD drawing by measuring all the dimensions on the print out.

SCAR-H CAD file:

   
  A 1:1 scale stencil  is taped into position along a straight edge.   Using a ruler and a permanent marker trace around the stencil.
   
The outline on the MDF.    Repeat the stencil, but this time flip it over and place it on the opposite straight edge. When the two halves are placed back to back the outline will appear on both sides making it a lot easier to cut out.    Draw some cutting lines on the panel and cut the excess off the piece of wood so that you only have small rectangles to work with.
   
Trace the stencil again onto the middle layer to be used, in this case 6mm plywood and cut off the excess so that you are left with three matching rectangles.   Clamp the three panels together and match them up using ruled lines from any perpendicular line of the outline.   Drill pilot holes and screw the three panels together.
   
I use a dropsaw to cut along  each vertical line, keeping the top edge of the work along the dropsaws guide.   Angled cuts can also be made using the dropsaw, the piece will need to be flipped over for some cuts.   You will need to use a jigsaw or bandsaw to make some of the cuts, as the dropsaw will not get all angles and positions.
   
Use a hole saw to cut any curved areas, such as the rear of the pistol grip, this will give a better finish.   Holes are drilled in the corners of the trigger guard, this creates a rounded edge and allows the jigsaw blade to cut along the lines.   Here is the body all cut out. The pistol grip and buttstock can now be rounded off using a belt or disc sander
   
The sides are cut out in the same manner, the two sides can be cut at the same time by screwing two pieces together.   Another view of the body showing the rounded buttstock.   Here we see the body after it has been routed. A rounding over bit is used to give the edges a nice finish. Not all edges are routed, the magazine and magazine well are left square.
   
This picture show the battery cover, which is yet to be routed.   Check positioning of all components and draw on all locations.   The LCD display and buttons are mounted to the side panel.
   
Internal sections are cut out. Some areas require all three layers be cut out while others may only need two.   Microswitch and trigger are mounted with tension spring.   A space for the speaker is routed out. A hole saw can be used to cut through the middle layer. This then acts as a guide to route out the other areas. Another holesaw is used to cut a clean hole to let the sound out.
   
A metal grill is held in place to protect the speaker.   Aluminium bar is used to hold the PVC pipe to the body   The aluminium bar is screwed to the outside of the MDF and to the inside of the PVC pipe.
   
Channels are cut into the body to allow for wiring.   Wires are taped into position so they are not damaged when the panels are screwed together.   The entire body is undercoated and sanded 2-3 times. This seals the MDF and gives a smooth finish.
   
Depending on the colour scheme some areas will need to be masked before spraying, apply 2-3 light coats of a good quality spray paint.   Another view of the completed paint job ready for all the electronics to be fitted.   The completed unit.