The Starlost - 15mm muzzle loading signal launcher

An easy to make and relatively safe launcher based off the Captain America 15mm originally designed by u/caffrinated. It uses .209 primers to propel the printed projectile and ignite the fuse making it useful as a pyrotechnics launcher, bear banger or signal launcher. If you have made a Captain America before, this should be an easy project.

Printed Parts & Settings:

BARREL - Walls/top/bottom: 10+ - Infill: 100% (Rectilinear) - Supports: NO (Outer brim is recommended) - Material: PLA+

FRAME - Walls/top/bottom: 5+ - Infill: 25% (Gyroid) - Supports: Organic Hybrid - Material: PLA, PLA+, PLA-CF (NO MATTE OR SILK)

REAR LEFT & RIGHT - Walls/top/bottom: 5+ - Infill: 25% (Gyroid) - Supports: Normal or Organic Hybrid - Material: PLA+

BREECH - Walls/top/bottom: 10+ - Infill: 100% (Rectilinear) - Supports: NO - Material: PLA+

STRIKER - Walls/top/bottom: 10+ - Infill: 100% (Rectilinear) - Supports: Organic - Material: PLA+

TRIGGER - Walls/top/bottom: 10+ - Infill: 100% (Rectilinear) - Supports: NO - Material: PLA+

STRIKER LATCH - Walls/top/bottom: 10+ - Infill: 100% (Rectilinear) - Supports: NO - Material: PLA+

BARREL LATCH - Walls/top/bottom: 10+ - Infill: 100% (Rectilinear) - Supports: NO - Material: PLA+

STRIKER GRIP x 2 - Walls/top/bottom: 10+ - Infill: 100% (Rectilinear) - Supports: Normal - Material: PLA+

SUPERCUP (Projectile) - Walls/top/bottom: 10+ - Infill: 100% (Rectilinear) - Supports: Normal - Material: PLA+

Hardware: 

Note on Hardware: The parts listed below 

Nuts & Bolts

2 x M3x8mm bolt

1 x M3x12mm bolt

2 x M3x20mm bolt

4 x M3x25mm bolt

2 x M2x8mm bolt or 2 x 2mmx8mm metal dowel

10 x M3 Hex Nut

Compression Springs

2 x Pen Springs (I used springs from BIC brand mechanical pencils) OD: <5mm, WD: 0.4-0.5mm, Length: 15mm

1 x OD: 10mm, WD: 1.0mm, Length: 55-60mm (I purchased a 300 mm spring from AliExpress and cut it down to the right length)

Other

1 x Penny (Canadian or American) or a 2 cent Euro.

Tools:

- Screwdriver

- Drill

- 1/4 Drill Bit

- 1/8 Drill Bit

- Soldering Gun or Iron

- JB Weld or Superglue

ASSEMBLY

1. Glue a pen spring into the frame for the striker latch.

2. Install the trigger and secure with fasteners.

3. Install the striker latch and secure with fasteners.

4. Use a soldering gun to heat press a penny into the front of the breech. Make sure it is flush with face of the breech and securely in place, JB Weld may be used if the coin fits loosely.

5. Use a 1/8 drill bit to drill a hole through the penny, use the hole in the back of the breach for alignment.

6. Install the assembled breech into the frame and secure with fasteners.

7. Glue the other pen spring to the rear of the barrel latch, place an m3 nut into the hexagonal pocket and push it into the pocket in the barrel. Secure with an M3x12mm bolt.

8. Use the 1/4 drill bit to chamber the barrel to a depth of 9mm, do not drill any further, you should NOT be able to see through the barrel.\

9. Place the barrel into the frame and secure with fasteners.

10. Install the striker pin (M3x25mm bolt) into the striker and make sure it is tightly secured with a hex nut.

11. Place one side of the rear frame onto the lower frame and slide the striker in, your striker pin should only protrude a couple mm.

12. Insert the striker spring behind the striker and place the other side of the rear frame onto the lower frame. Secure with fasteners.

13. Place the striker grips on the exposed striker area and secure them with M2x8mm screws.

14. Pull back on the striker grips and make sure that the striker securely latches in place. It should slam forward when the trigger is pulled.

LOADING SUPER CUPS:

1. Super-glue a fuse into the bottom, making sure that at least 5mm of fuse is exposed and cut at 45 degree angle to increase surface area.

2. Load the cup with your choice of payload (Chalk, Black Powder, Fireworks Stars etc.).

3. Snap on the lid.

Projectiles should easily fit down the barrel.

ENJOY and if you have any issues please reach out to me on reddit.