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Buzz Bee Plasma Blaster Mod - HALO Assault Rifle

Updated on October 17, 2011

Buzz Bee Plasma Blaster Modified to look like a HALO Assault Rifle

I purchased a Buzz Bee Plasma Blaster a few years ago and modified it to look like a HALO Assault Rifle.

Although the Buzz Bee Plasma Blaster is shorter than a full-size HALO Assault Rifle, this is a quick and relatively easy solution if you don't yet have a weapon for your HALO Master Chief armor.

Buzz Bee Plasma Blaster - HALO Assault Rifle Finished
Buzz Bee Plasma Blaster - HALO Assault Rifle Finished

Buzz Bee Plasma Blaster - The Mod

A couple of years ago, I made a set of Master Chief armor for Halloween. The one thing I was missing was a weapon. After searching online, I found someone who had taken a Buzz Bee Plasma Blaster and painted it black. Plain black, and it looked pretty good, but I wanted to take it a step further. My plans: 1. Add a counter. 2. Replace the barrel. 3. Replace the flashlight. 4. Better paintjob, not just black.

Step 1 - Markup

Using a Sharpie, I markup the sections of plastic I want to remove. The counter area needed to be cut out, the orange barrel needed to be removed, and the light needed to be removed.

Step 2 - Dis-assembly

The Buzz Bee Plasma Blaster is very easy to dis-assemble. Only about 20 screws holds the two sides together.

Step 3 - Cutting

Once the gun is dis-assembled I cut out the sections that I marked for removal. I used a coping saw to cut the pieces, but a Dremel with a cut-off wheel would have been better.

I put the gun back together for a test fit and noticed the area for the flashlight is blocked by a screw mount. Using some pliers I cut out the offending piece.

If you are careful with your cuts, there is no need to fill-in any unnecessary holes or gaps.

Step 4 - New Flashlight Mount

Using a toilet paper holder from K-Mart, I used the hollow tube to create a flashlight mount. I didn't want the flashlight permanently attached, fortunately the tube I used was a perfect fit. If you don't have a perfect tube for your flashlight, you can add layers of felt to the tube to create a friction hold. The tube is secured in place with hot glue.

Sorry, I forgot to take pictures of this part.

Step 5 - Counter

Using some parts from eBay and Radio Shack I made a simple display. The parts cost me about $25 and it's just a static display that turns on and off. I found out later that for about $10 more I could buy a ready made counter online (Westaby.net). Trust me, just buy the counter.

The counter barely fits in the section next to the battery compartment, and I am forced to cut a few pieces of the battery compartment to fit the display.

The counter, electronics, and new battery holder are secured in place with hot glue. I mount a push button switch to the left side of the gun so I can activate the display.

I also cut a clear CD case to make a cover for the display. I painted the back of the CD case black (masking out a section for the counter) so I wouldn't have to worry about painting the display area. I mounted the plastic cover using three small screws.

The above picture is the counter area without the CD cover.

Step 6 - Replace the Barrel

The gun tip of the Buzz Bee Plasma Blaster lights up via an LED. I kept the LED wired and used a small section of PVC as a replacement barrel. I secured the PVC with hot glue first, and then filled in the area using Bondo. It's not necessary to fill the area with Bondo as long as you secure the barrel.

Here you can see the LED and the barrel before I cut it. As you can see, the barrel is hollow. I mounted the PVC to the LED holder using hot glue, and then I filled the orange section with Bondo around the PVC.

Because I used PVC pipe, the LED lights up the barrel when the trigger is pulled.

Step 7 - Paint

The inside of the gun is pretty bare. You can completely dis-assemble the rest of the gun by removing a few more screws. Complete dis-assembly allows for an easier paint job.

Some Buzz Bee Plasma Blasters have a logo molded on the side. I used some sandpaper to remove the molded logo.

Step 8 - Re-assembly

Once the paint had dried I reassembled all the pieces. For about $70 (Gun, Electronics, and Paint) and about 20 hours of work, my Buzz Bee Plasma Blaster went from a green toy gun, to a HALO Assault Rifle, which I sold on eBay for over $200. Too bad Buzz Bee doesn't make the Plasma Blaster anymore. Trust me, I've contacted Buzz Bee directly and they do not manufacture the gun anymore. You may be able to find some old stock at Toys-R-Us or if you're lucky online at Amazon.

Here is the finished gun with a silver Mini Mag Lite installed.

See the video of the finished gun.

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