Custom Case Design Help! PICTURES!!!!! 56k!

[HotDog-Cart]

Hey guys. I'm designing something, that actually needs to get done. Its a mod for my Airsoft Gun. Right now, I have a standard AK47. (Its a Aftermath Kraken). Looks like this But all black):



What I'm doing is some modification to the stock on the gun. I'm making a custom grip/stock essentially, heavily based off of the Egyptian Maadi RML. (Nevermind the wood on the picture. I am using ABS/Plastic)

So, I need the stock to look like this basically:



From my other failed projects, I already have most of the "Ingredients".

I have:

Hot Glue
Hot Glue Gun
Donor Case
Epoxy (JB WELD. Comes in two seperate tubes. Mix together)

I want to basically do a frankencase mod to the stock of the gun, and make it look pretty good.

Questions:

I have little idea on how Epoxy and Bondo work. Epoxy is a adhesive, is Bondo?

I know epoxy can hold stuff together just like hotglue, but can I sand it? (I know you can fill cracks and such with bondo, and sand it, But can I do the same with Epoxy/JB Weld?)

How hard do you think this will be to do?

Do I need bondo to make a smooth look on the seams? Or can sanded epoxy do the same thing? (Bondo is like $20-$30. Too expensive for this one time use.)

[vskid]

So you're pretty much just connecting the bottom of the grip to about the middle of the stock? I'm not sure how much abuse that part would have to take, I would use a big bolt or piece of rebar to connect the two pieces structurally (make a hole in the case so you have as much bolt/rebar in the case as possible). Then the bondo/epoxy would be purely cosmetic and you won't have to worry about the whole piece falling off.

[HotDog-Cart]

Attach rebar to plastic? Seems a little overkill.

Mind you, it would be hard to do that. The stock is hollow (to hold a 8.4V battery), and the handle has gear mechs inside.

[vskid]

There is no such word as overkill. But that does make this tricky.
Hailrazer always suggests bumper filler for large areas because it will flex instead of crack, with a thin layer of bondo to fill in the imperfections.

[HotDog-Cart]

Sweeet. VS, do you have any awnsers for my other questions?

[Mr BadWrench]

You know people throw away stock thumbhole stocks because they are so uncomfortabe. I suggest looking for an actual stock.

[HotDog-Cart]

What? I'm not going to buy one, as they arent even made for airsoft, I believe.

Plus, I want to make one. I just ned some questions awnsered.

[HotDog-Cart]

Bump. Still need these questions awnsered.

[HotDog-Cart]

Another bump.

[HotDog-Cart]

This thread is starting to become a hotdog party. C'mon guys, awnserrrr.

Pictures of cardboard mockup: