We began building the 10 mm pistol from Fallout 4 after watching the first season of the Fallout TV series, although it had been a project we had wanted to take on for a long time. While many replicas already exist, our goal was to approach the build the same way stunt weapons are produced for film, focusing on safety, durability, and repeatable casting.
The main body of the pistol was cast solid in urethane rubber, allowing the prop to withstand drops and on-set handling without damage. Certain components, including the sights and trigger guard, were produced in SLA resin to maintain sharp detail in thin areas that would not translate well in rubber.
Seam lines were cleaned using a Dremel with a stone bit before finishing. The surface was primed with a flexible primer, followed by layered paintwork using a mix of wax finishes and inks to create the rusted, worn appearance seen in the game.
Each replica was packaged in a custom box with a fitted foam insert and carrying handle, providing protection and making transport easy.
