Han Solo DL-44 Complete Blaster, Battle Worn Finish

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Expected release date is 1st Jun 2022

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Features include:

  • Custom made Hensoldt-Wetzlar scope made of all original materials, and real optical lenses! More than 27 individual parts!
  • Grille made of 3 hand-cut Veron model kit cylinders
  • Denix C-96 Mauser replica customized especially for this prop
  • Steel bull barrel complete with threads for the rifle barrel extension (as seen when the original gun appeared in "Naked Runner")
  • Custom made steel MG81 flash hider and mounting collar
  • Steel scope mounting bracket and hardware
  • Barrel greeblies made of PVC and ABS plastic
  • Functioning hammer, trigger and bolt!
  • Real walnut grips, stained and weathered
  • Brass grip escutcheons and blued steel screw
  • Trigger, hammer, and bolt are stripped and finished grey. 
  • Bolt extractor shape is blued onto the bolt
  • Raised bosses on the Denix sight mounting pin are removed and proper countersink added
  • Top of rear sight bar is milled flat to remove the added Denix "lump"
  • Entire Denix is stripped, polished, and reblued before aging
  • All seamlines are ground off

Now THIS is a good blaster to have at your side!  Perfect for display, conventions, collecting, or just because it's cool!

Our Han Solo DL-44 Blaster is the result of a years of fanatical research. We've procured all of the original elements that are currently available including Veron model kit cylinders and pushrods, Hensoldt-Wetzlar scopes, and MG-81 flash suppressor and adapter. We've spec'd them all in minute detail. We've searched out the best manufacturers for each of the parts required to duplicate this prop, down to the screws. What we're offering here is incredibly close to the real prop.

How fanatical?  Well, we've reproduced every detail that can be reproduced, even those details you will never see. Such as the bull barrel threaded at both ends (the original custom Mauser was made for a Frank Sinatra spy movie and had a detachable rifle barrel.)  Such as a COMPLETE Hensold-Wetzlar scope with ALL INTERNAL PARTS, painted or left bare exactly as the original scopes. Such as using 3 Veron cylinders to construct the "grille" instead of making an easier, simpler (and cheaper) one piece grille. We've duplicated every scratch and chip that is visible in the few reference photos that are available.  The scope mounting nuts have straight knurls. The scope tubes are real steel, not cheaper and easier aluminum. The scope adjustment knob has a hexagon pattern knurl. 

We start with a zinc metal model gun made by Denix in Spain.  We completely disassemble it, and saw off the barrel.  We drill a perfectly centered, perfectly aligned hole for the new barrel using a milling machine and custom jigs.   Then we mill the face of the receiver perfectly flat and perpendicular, and thread it with real gunsmith threads. The zinc gun parts are all hand polished to remove all of the Denix finish. The barrel extension is then machined to remove the raised bosses around the rear sight retaining pin, and the holes countersunk like the original. The Top of the rear sight bar is machined flat to remove the lump that shouldn't be there. The inaccurate firing pin is ground off of the bolt retaining rod, and re-blued, The rear edges of the frame are radiused like the original. In preparation for the new, more accurate walnut grips, the brace in the center of the grip frame (for the plastic grips) is cut away and filed smooth. All seamlines are ground away and faces flattened. The scope bracket mounting holes are then drilled and tapped. The frame, barrel extension, and rear sight are then re-blued. The bolt, trigger, and hammer are tumbled to a gray finish. The extractor shape is added to the bolt with bluing. The blued parts are then hand aged with steel wool. All zinc parts are then sealed with dry oil. Then we hand-chip the paint on the ends of the scope and elevation adjustment knob. The scope is tumbled to introduce random dings and scuffs. The scope mounting bar is silkscreened to reproduce the chipped pattern on the original. The scope bracket and rings are tumbled and hand-aged with various abrasives. The thumb screw for the bracket is tumbled and sealed with dry oil. The gun is reassembled and a tumbled "bull" barrel is hand-matched to it and installed so that it rests at the perfect angle of rotation without any gap. We pre-assemble the thumbnuts and studs with thread locker, we tumble them then grind away the blued finish on the outer face. We mount the scope bracket with the thumb nuts. To match the angle and details of the scratches of the original blaster, we use a masking template to paint them while in place. We add the distinctive scratches to the rear outside of the scope, and burnish the flash hider to a dark grey finish.  A flash hider mounting collar replica is fitted to the barrel, and the flash hider installed. The Veron cylinders are cut, assembled in a custom jig, hand shaped, then glued to the magazine well. The rear sight is glued to the top of the gun to hold it down (real Mauser sights have a strong spring to hold them down. They don't "flip up"). The greeblies are assembled and glued to the top of the barrel. New walnut grips are hand sanded, stained, the brass escutcheons aged, then installed on the gun. Done! It's a crazy, crazy amount of work, but we are always striving to make the "battle worn" version the best replica we can make.

Grab one of these beautiful props while we can still make them available!

Please note that this replica does not hold or fire real ammunition.

Disclaimer: Despite copying the lenses from real original Hensoldt-Wetzlar scopes, they unfortunately do not focus for distance.




Do you ship internationally?

Yes, we do.  But we do not know if these are legal in your country.  That is for you to find out.

What about customs?

Paying the import duty your government imposes is your responsibility.  Import duty is determined by your government after the shipment arrives in your country.  We have no idea what your government will charge you to import anything we sell.  We will not refund you the shipping charges if the parcel is returned because you refuse to pay import duty.

How much is shipping to the UK?  Finland?  Botswana?

Add the item to your shopping cart, go to your cart, then enter your shipping address.  You will see real time quotes from USPS and UPS with the available service options and prices.  These are the ACTUAL charges with nothing added.  We make no money on shipping.  

Do you ever have trouble shipping these to another country?

Occasionally, yes.  We do sometimes experience delays with blasters going through customs, since they are difficult to classify.  It is not unusual to experience delays up to two months in customs.  USPS shipments are delayed more often than UPS shipments.  About 80% of our shipments get through as expected.

Do you offer tracking?

Yes, both USPS and UPS offer tracking.  USPS tracking is quite limited.  After the parcel arrives at your country, your government's customs department takes possession of it.  USPS can't track it beyond this point.  After customs has  inspected, classified, and taxed it,  it is handed over to a local delivery service.  This agency will collect the import duty and arrange delivery.  You may be required to pick it up.  UPS offers better tracking because they handle the package from door to door, including collecting the import duty.

32 Reviews Hide Reviews Show Reviews

  • 5
    Han Shot first... and now so can I

    Posted by Carter Kingery on 23rd Jan 2021

    I can not speak more highly about Todd's Costumes and highly recommend them for any of their products. As for the product, this was my first purchase and the blaster is well worth the money for any Star Wars fan. The DL-44 has a great weight and feels so incredibly real (especially when you can cock the hammer back and pull the trigger to get that satisfying click). My only Gripe is that the scope does not work, but that is something that is fully disclosed on the product description. As for the service, Todd's Costumes went above and beyond. To be upfront it 3 months to get my product, but Todd's Costume's was transparent about the delays due to a manufacturing issue, and Covid-19 slow shipping. But not only were they upfront and honest, they also allowed me every chance to refund my pre-order, and to reward for keeping my preorder they upgraded me to the full wooden grips. As I said a the top they produced a fantastic realistic product, and they provide above and beyond service.

  • 5
    dl-44 complete blaster

    Posted by les wagley on 17th Jan 2021

    Stunning...Beautiful....and amazing, all of my friends i have shown this to, and let them hold it , are jealous. Due to covid it took a little bit longer to arrive , but well worth the wait and Todd kept me informed throughout the whole process. Thank You...Thank You...Thank you

  • 5
    DL-44, Battleworn

    Posted by Zachary Reinsel on 4th Jan 2021

    Fantastic quality. Nice weight to it. I feel obligated to say "pew pew pew" whenever I pick it up.

  • 5
    DL-44 Blaster

    Posted by Jamie C on 21st Dec 2020

    Like everyone else who has purchased this blaster I can’t say enough about how incredible it is. An amazing work of art. You will not be disappointed if you decide to purchase.

  • 5
    Gift for a big Solo fan.

    Posted by Adam Acuna on 27th Oct 2020

    I bought this as a bachelor gift for my best friend, a big Han Solo fan, and he absolutely loves it. If you're looking for a quality, metal, replica with as much attention to detail as possible, and not some 3D printed hunk of plastic. I highly recommend this for any Solo fan.

  • 5
    Nothing beats a good blaster at your side

    Posted by Thor K on 14th Aug 2020

    These guys aren't kidding-- this is the most accurate prop replica you'll find for the money. It's incredibly satisfying in-hand. I'd like to note that my blaster initially shipped with a production defect-- Todd and his staff communicated closely with me to resolve the issue and I commend the way they stand behind their work.

  • 5
    Exceeded expectations

    Posted by Andre S on 28th Jul 2020

    Took a gamble and purchased this to complete my Han TFA costume. Very pleased with the build quality and attention to accuracy. It's a teensy bit on the heavy side (almost 2kg) but that actually helps it stay in the holster since they did away with the safety strap in the movie. Highly recommend this blaster to anyone looking for a movie-accurate display or an authentic costume experience.

  • 5

    Posted by Dennis Marzi on 7th Jul 2020

    Absolutely amazing replica!!! There is just no substitute for holding a prop with the correct weight!!! This replica is perfect and looks great sitting next to my DL-44 Greedo Killer!! I will be buying more in the future!! Thanks!!

  • 5
    Han Solo DL-44 Battle Worn

    Posted by Brian Park on 30th Jun 2020

    Absolutely beautiful work of art! Amazing customer service. I’ve waited years before purchasing a DL 44. After years of research and finally finding this one, I know I made the right purchase. Thank you!