I started by making my own set of blueprints, making some small adjustments where I knew I had problems with the previous ones I had made. Then I got to work, cutting out the core with the 1" thick foam.
I also tried something new here, gluing all the pieces together with contact cement rather than super glue. Much better bond - those pieces will never separate!
Once that was all together, I cut apart the blueprint even more, for the layered 1/2" foam.
I still curved the top pieces with the router, though that was quite a bit scarier as I had to do them a piece at a time with a guide stick. In the previous one I had plenty of protection from the router bit with the 4 layers of foam, but with this I was a lot closer to it.
I survived though, and this was the result:
After that I threw on the barrels, sight, and craft foam raised details, and off to the Plasti Dip it went!
It's really nice seeing the progression of skill level, from the first, to the one that really put me out there, to this newest one that is the most correct version I've made. I hope you guys enjoy it as much as I have! Here's some final pictures to show it off some more. ;)