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Old 01-08-2008, 08:03 AM #1
Jornum1
 
 
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Custom Milled Aluminum Tactical ION XE Body

Updated pics and specs towards the end of the thread. This is a ongoing project
Hello everyone, I bought a new ION XE in December after a long lay off from playing paintball. I haven't played in over 7 years. I used to be a regular with a pretty tricked out cocker. I hurt my back pretty bad and had to give up all my fun activities for a few years. I never picked paintball back up again until this fall. A few friends of mine play regularly and have peaked my interest again. I have taken a particular interest in woodsball and scenarios. I have yet to attend a big game, but will be going to my first at Top Gun in NJ this Sunday(Jan 13th).
Anyway, I work for a family business that has a small machine shop, and I have basic knowledge of machining. I was going to buy a blackcell or deadlywinds tactical body, but then being the wannabe engineer I decided to give it a whirl on my own. We had a length of Hex sided aluminum rod laying around that was already bored out to 1" diameter inside. Its material I was told has been sitting around since the 60's and we will never use again, so it is at my disposal.
I started out by boring it out the the diameter of the ION's breach. I then started milling off material. I probably had a good 3/8" of material on each side. After some preliminary milling I drilled a 1" feedneck hole and threaded it.

After that I milled out the bottom and located the mounting holes for the grip frame. I also angled the front. I left the front end long so I could mount the Qloader there(waiting for parts for that), and it also covers the insert color of the freak back on the barrel.
I purchased a Trinity folding stock for a Tippman 98 and mounted that. It is held in by a Allen set screw, so it can be removed easily to access the BOB feature of the XE.
Next I am making a riser for a red dot sight behind the feedneck.
I have a lower profile 90 degree elbow coming in the mail from Qloader so it wont be quite as tall.
What do you guys think? Remember I am not a professional machinist, and this is my first attempt. There is still a lot of work that needs to go into it. I am also going to mount a 2" rail on either side of the barrel for a tac light, laser sight, ect. This is just the basic shape. I am probably going to slot the sides vertically to break up the straight lines and reduce weight, and it will be painted of course.
This is where I am at right now. I will get some better pics when my wife gives my camera back! She is a camera hog. These 2mp cell phone pics aren't too bad though.
It is completely functional, and fires great! It has a great feel to it, like a real rifle. When I get the riser on the top, and the slots milled, it wont look so round.







Last edited by Jornum1 : 03-08-2008 at 04:27 PM.
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Old 01-08-2008, 08:38 AM #2
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very nicely done. how heavy is it?
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Old 01-08-2008, 08:52 AM #3
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I threw it on the scale before I cut about 2 inches off the end and milled it down some, I believe it was about a 1 1/2lbs. So I am maybe at 1.375 or something like that(just a guess) Like I said before I still have a lot of material to take out of it still. That is just the basic shape. I am going to put some vertical slots on the sides that will take a good chuck of weight out of it. Its not bad with the stock though. It feels like a rifle, I like that being a person that grew up shooting real guns.
I will post some more pics of the riser later today.

And thanks for the kind words everyone, I appreciate it!
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Old 01-08-2008, 09:09 AM #4
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what was the final inside diameter?


also have you thought about moving the entry to the breach to the side like and old mag
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Old 01-08-2008, 10:27 AM #5
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what was the final inside diameter?


also have you thought about moving the entry to the breach to the side like and old mag
I would have to measure again, I dont remember exactly. I believe it was just over 1.5in.

I did think about the side entry into the breach, but I didnt want to modify breach. I wanted to keep the internals as simple as possible. I like the idea of a riser for the sight though. It will give it more of a M-16/M-4 look.
This will probably be my prototype. After I finish and start to play with it I am sure I will think of a million things I would change for the next!
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Old 01-08-2008, 10:41 AM #6
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interested to see how it turns out. it looks decent as is lol. do post when you get a sight on it.
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Old 01-08-2008, 12:33 PM #7
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you could mill that down pretty nicely and make it look really nice. its still bob now right? good job post end pics when ur done
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Old 01-08-2008, 12:43 PM #8
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Yea its still BOB, You just need to loosen one set screw for the stock and it comes right out.
Thanks everyone, I will post some more when I make progress.
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Old 01-08-2008, 01:06 PM #9
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In my head, I can see all kinds of potential to come out of this project. There are so many options as far as designs and whatnot, depending on your machine skill level. you could even do a two part, where the inside is a solid piece of black stock, and you do a cut/mill flames or some pattern/design into the outside sleve that would be polished or anno'ed. hmmm...i may have to pull out the old shop smith... keep up the work for sure!
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Old 01-08-2008, 01:20 PM #10
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That is a great idea, but I want to keep this project all business. My goal is to have it look as mil-sim like as possible, but still original.
Machining flames is definitely beyond my skill level! I mean I guess I could do it free hand, but that is besides the point.
You do give me a idea though. I am thinking of sloting the front of the body all the way through in the sides or top and bottom, back to where the breach starts. That would give cool look, like a shroud effect.

I will probably just do a quick flat black for color for this weekend, but eventually I would like to do a dura coat digi-camo paint job.
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Old 01-08-2008, 01:49 PM #11
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nicely done. though I prefer tilted feed neck like SP8. Couldnt find anybody make that type of breech and body for it.
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Old 01-08-2008, 02:01 PM #12
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Do you plan on doing more milling and getting it anodized?
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Old 01-08-2008, 03:08 PM #13
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nice gun bro and very creative
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Old 01-08-2008, 04:25 PM #14
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try to make a rail to mount a scope/laser sight. Seeing as your into woodsball.
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Old 01-08-2008, 04:54 PM #15
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I stated above I am making a riser for a weaver rail to mount a red dot sight.
I also stated above my plans for digi-camo paint.
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Old 01-08-2008, 04:57 PM #16
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Quote:
Originally Posted by Jornum1 View Post
I stated above I am making a riser for a weaver rail to mount a red dot sight.
I also stated above my plans for digi-camo paint.
Good luck with that.
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Old 01-08-2008, 05:10 PM #17
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nice job well done.
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Old 01-08-2008, 05:35 PM #18
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looks great..... a lot like the deadlywinds body i own

how are you going to finish it, anno, powdercoat or paint?
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Old 01-08-2008, 05:36 PM #19
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Quote:
Originally Posted by Adidas4275 View Post
looks great..... a lot like the deadlywinds body i own

how are you going to finish it, anno, powdercoat or paint?
digital camo paint.
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Old 01-08-2008, 07:17 PM #20
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Thanks Everyone,

Quote:
Originally Posted by Adidas4275 View Post
looks great..... a lot like the deadlywinds body i own

how are you going to finish it, anno, powdercoat or paint?
Yeah the deadlywinds body would have been my choice if I bought one. But even if I wanted to no bodys work with the xe yet.

When I slot it and finish it up with the sight riser and everything it will have a distinct look(hopefully!).
And yes I am going to paint it with duracoat digital camo pattern. They have a nice kit with stencils and everything you need.
/http://www.houtsenterprises.net/
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Old 01-08-2008, 07:37 PM #21
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That is going to look great. Make sure to post pictures after paint.
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