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2 posters

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE)

    Johnnus
    Johnnus


    Posts : 204
    Join date : 2010-08-16
    Age : 25
    Location : Glen Waverley, Melbourne (VIC, Aus, Earth)

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) Empty Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE)

    Post  Johnnus Thu Sep 13, 2012 10:49 am

    Hey guys,
    So when in Malaysia in the summer hols of 2011-2012, I found a whole bunch of Berserkers sitting in several TRUs. I also spotted stuff like Rads 12s, Rogues and Tetra Strikes etc but I was tight on space so I only managed to get one Zerker and 2 Jolts. Besides, of all of them the Zerker was the one I most wanted (as with the Jolts).
    Anyway, I've only recently decided to properly mod it, and I decided to do a full writeup on how I did mine.

    NOTE: Sorry for the terrible pics, I used my iPod Touch.

    TOOLS REQUIRED:
    -Screwdriver (of course)
    -Hacksaw (dremel works just as well)
    -Dremel
    -Hot glue gun
    -Drill
    -Ruler
    -Pen/Marker (for marking barrel lengths)
    -Claw Hammer

    MODS:
    -Rebarrel
    -Handle Replacement
    -Extra Spring

    *INTERNALS*

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 253530_521975571151498_103020608_n
    Shot of the (mostly) stock blaster. At this stage I'd removed the dart pegs, added a small tac rail and sliced down the rocket launcher for a coupler.
    The orange shell pieces can be removed when their respective screws have been removed.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 303127_521975601151495_146147662_n
    Open. There are a number of screws, one of which is under a sticker. In the first pic you can see the hole I punched with a screwdriver to get at it.
    There are four larger screws which go into:
    -Top right screw port
    -Bottom right screw port
    -Left most screw port
    -Middle upper screw port

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 534311_521975621151493_984820803_n
    Close up of the air tank area. So far as I can tell it's basically a 4B with lever trigger.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) Photo.php?fbid=521975654484823&set=a.521975541151501.142592
    Close up of the plunger, turret and rotation mech. The large, short spring pushes the plunger tube against the turret.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 488293_521975694484819_1230821429_n
    The massive turret.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 297893_521975731151482_77631755_n
    The dual triggers. Note how the airgun trigger (front) has popped out of place. I haven't modified it - it pops out of place when stock. It can make reassembly annoying, but it will be rectified later.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 285484_521975761151479_1587820268_n
    Close up of the spring holding the lever trigger in closed position. It's a pain to put back into position once removed, so be warned!

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 394310_521975794484809_1116144926_n
    The turret and entire airgun assembly come out as one. This is because the airgun barrel supports the rotation mech and turret.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 394194_521975821151473_2023784512_n
    Without the airgun and turret, the shell is suddenly almost empty.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 427850_521975871151468_49439700_n
    Exploded view of the rotation mech. In order from left to right:
    -Main rotation mech piece (links to plunger assembly)
    -Gear thingy that latches to turret
    -Spring which compresses turret outwards against shell (for rotation mech) (surprisingly strong)
    -Turret (duh)

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 393254_521975907818131_718983786_n
    Turret from a different angle.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 285559_521975931151462_715759383_n
    Down the front of the turret. Note how I've epoxied on a 25mm coupler and removed all the air pegs.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 548014_521975954484793_1774810480_n
    Turret with inner cylinder thingy removed. There are 5 screws holding it in, but they're easy to get at.



    *Rebarreling*

    CONSUMABLES:
    -Barrel material of choice (minimum 1m worth, probably better to have 1.5m+) - in this writeup I used 16mm UPVC because it fits stock darts nice
    -Hot glue

    *NOTE* Anywhere where UPVC is mentioned can be replaced with your barrel material of choice.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 408370_521975991151456_381244670_n
    I used this much UPVC because it's all I had. I think you get better performance from longer barrels than what I used.

    Before cutting into the turret, remove the pegs. This is easy, just drill down the hole in the base of the turret. Don't enlarge the hole - you might mess up the seal. Once the peg's out, clean it up with pliers, screwdrivers, whatever. Repeat for the rest of the air pegs.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 184171_521976027818119_640613230_n
    First of all, cut your stock barrels around the mark. I think it's just under the 1cm mark from the base of the turret.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 560963_521976101151445_240777208_n
    Part way through it. It's really tedious with a saw, but I don't trust myself with a dremel cutting disc (and I love using saws).

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 377874_521976171151438_268007384_n
    Completed cut.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 523200_521976274484761_1982786038_n
    You can see the height differences here. On the right is the base you just cut out, on the left the rest of the stock barrels.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 427805_521976354484753_1574136705_n
    16mm UPVC fits in tight in the base 'cups'.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 581521_521976621151393_1335206346_n
    I cut my barrels to around the 5cm mark (2"). More popular lengths are 3" (7-8cm) but 5cm was the longest I could do (ran out of UPVC).

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 399135_521976864484702_311061129_n
    Fit stock darts pretty good.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 561526_521977091151346_1631529109_n
    Next, cut the remainder of the stock barrels just underneath this part. You don't want to cut above because you'll lose the screw ports, which are essential to the blaster.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 392505_521977457817976_1147669094_n
    Half way through. Note how the inner ring is also cut. This is ok - the screw ports are still intact.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 377344_521977511151304_1968059624_n
    Complete. On the right is the useful part, on the left some useless plastic. Go ahead and make it into a paperweight or something.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 223877_521977547817967_522995279_n

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 246646_521977607817961_1547788081_n
    The section you just cut off should still fit on the giant cylinder. These are why the screw ports are essential - they hold the turret onto the rest of the blaster.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 546070_521977711151284_1468047806_n
    The waste plastic from slicing the turret apart. It was more impressive in real life.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 427784_521977764484612_1749570313_n

    Cutting out barrels...
    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 395346_521977814484607_344074475_n
    Test fitting barrels. They fit real tight, but I didn't like it.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 381130_521978021151253_1561509007_n
    All 20 barrels cut ready.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 271170_521978054484583_833701854_n
    If necessary, sand one end of the UPVC so it fits nicely in the base without being too tight.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 523360_521978084484580_1251020018_n
    All twenty barrels test fitted.

    There are two methods of rebarreling. The first is sanding the inside of the cylinders on the front part of the turret out so they fit the new barrels, like so.
    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 253180_521977731151282_2031134794_n

    I couldn't be bothered though, it took too much time. So instead I did this.
    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 423799_521978121151243_1205609731_n
    Cutting off segments of the top turret part, the remainder of the stock barrels would form 'cups' which would hold the barrels in place.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 263992_521978154484573_119712370_n
    All cut down.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 284575_521978194484569_1350075952_n
    Sand the teeth down like so.

    Now when I tried assmebling it as is, it didn't work. The cups were too small. If you're not using UPVC you might not need to do this, but sand the cups out like this:
    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 218056_521978291151226_391467165_n

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 303102_521978251151230_364780698_n
    Close up. Right is sanded, left unsanded.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 310316_521978234484565_471662279_n
    Test fit like so. The top ring should not be trying to push the UPVC outwards.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 295198_521978317817890_814338565_n
    Complete! Even without being glued and properly assembled this is quite menacing.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 419281_521978347817887_1098417060_n
    Begin gluing in the barrels to the base. I used hotglue. Make sure it's an airtight seal around the barrel.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 548103_521978391151216_11197556_n
    Half way there...

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 223171_521978427817879_2014658754_n
    Complete!

    Now for the top piece....
    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 303776_521978467817875_2060002295_n
    It should fit in neatly like this.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 250271_521978484484540_2064922336_n
    Test fit the entire turret (blutack the front part to the barrels) to make sure it fits fine in the shell. Push the base of the turret back into the plunger outlet.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 394310_521978507817871_421999508_n
    Like so.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 297806_521978537817868_1562209288_n
    Lift the turret assembly out without moving the front piece and glue it.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 561000_521978561151199_330402293_n
    If necessary sand the outer edge of the turret so it doesn't catch on the shell.

    The rebarreling is complete!
    Reassemble and test fire the turret. If that's all you wanted to do go ahead and close this window. If you want to do even more, continue.


    *Handle Replacement*

    EXTRA CONSUMABLES:
    -Sacrifice handle (I used LSFG)
    -More hot glue
    -Epoxy (strongest one possible)
    -Several screws
    -Hot glue/Epoxy putty (optional)

    Most of you know how childishly small the Zerker's handle is. We're going to fix that.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 551765_521978591151196_1524201262_n
    LSFG handle compared to the Zerker's. See how much larger it is?

    Cut the trigger of your LSFG handle down, and drill a hole in it like so:
    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 546435_521978641151191_121546187_n
    I used I think a 1.5-2mm drill bit.
    A wire goes into the hole which releases the plunger catch.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 387124_521978667817855_1945507417_n
    Test fitting the trigger.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 284455_521978704484518_1885563611_n
    Begin cutting off the Zerker's handle like so.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 246783_521978737817848_577006212_n
    And decapitate it at the trigger guard. Don't cut the trigger guard off though, it's useful. It holds the triggers on rails.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 297873_521978751151180_1426619561_n
    Cut the LSFG handle down to this.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 10471_521978804484508_1981905269_n
    Test fitting, no glue. You'll need to do some trimming on the Zerker shell and LSFG handle to accomodate for the trigger.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 534268_521978827817839_1291577028_n
    Glueing it with hot glue. This is merely to hold it in place for the rest of the mods.
    Once it's in a good place epoxy it like your life depends on it.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 281943_522315481117507_708264313_n
    The way I attached the handle resulted in the airgun trigger being too far back. This is an easy fix, just trim the Zerker shell so you can move the trigger forward, and hot glue the rod it is attached to. This alignment the air fully releases as the airgun trigger just touches the springer trigger.

    Once the epoxy has dried, you'll want to reinforce the handle by securing the handle to the body of the Zerker with several screws. This is essential as I've had the handle break off with just epoxy. Make sure not to damage any internals with the screws or screwports. Unfortunately no picture of this step, but you get the idea.

    You can use hot glue or epoxy putty to fill in any gaps, and reinforce the handle-shell join.

    Once the epoxy has fully cured and the screws are all in, you're done! Your Zerker now has the handle of an LSFG (or whatever you used) and not that useless tiny stub it used to have.


    *Spring Addition*

    EXTRA CONSUMABLES:
    -C-756 Spring (Bunnings, about $7)

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 271021_521977837817938_1833693193_a
    Remove the plunger from the shell. It's a direct plunger (yay!).
    Take careful note of how everything fits together.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 253479_521977874484601_513723775_n
    Using a claw hammer pry off one of the green caps. It'll come off eventually.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 3390_521977884484600_926395945_n
    The plunger system disassembled.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 421590_521977914484597_1487715808_n
    I added a C-756 spring (from Bunnings) as it was the best fitting spring I had in my box of springy fun. The load of it is less than an NF's spring, and it fits perfectly inside new gen NF springs.

    *Other Stuff*

    I didn't play with the seal because it is already great (almost perfect). Buzz Bee were also kind enough to pad the plunger with a rubbery thingy. It's really tough and probably actually absorbs impact. I was too lazy to replace it in any case.

    The plunger-outlet-turret seal is also great so I didn't play with it.

    By now you're probably wondering why there's no writeup for modding the airgun. I didn't do this because I'd already modded my airgun, and the process is almost identical to that of a 4B (which is all over the interwebs). The only precaution is not to cut the barrel too short because it supports the turret and the rotation mech. Other than that, it's basically:
    -Saw off the tip
    -Slap on a coupler

    If you want to attached a shoulder stock (for ease of priming, aiming and stability), I suggest a look at iamthatcat's writeup on attaching a Praxis stock to a BBUMB handle. The Zerker's handle is pretty much the same so the same processes can be applied.

    Not pictured, I drilled out the Zerker's plunger output hole. I used a drillbit barely larger than the outlet. The important part is that there's a smaller orange piece within the plunger output piece which restricts airflow, so drilling it out slightly increases ranges. Beware not to mess up the seal though.

    Another mod you might want to consider are attaching sling points. This is easy, just drill holes in the shell and put in eye bolt thingies. Hot glue if necessary for reinforcement.
    I've done this to my Zerker (not pictured). It's really quick and simple, and allows the use of a sidearm. Why you'd need a sidearm with the Zerker though is beyond me.


    *Completion*


    Once everything else is done, relube the plunger o-ring (as usual), and if you want relube the pump o-ring. I didn't bother.

    Now reassemble your Zerker (after the various glues dry/cure fully).
    For some reason mine was reluctant to be reassmebled but with some persuasion (ie brute force) it submitted and closed.
    If you've done everything right you'll end up with one beast of a blaster.

    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) 402230_522344157781306_835846743_n

    My ranges: Unconfirmed - these are based off velocity/impact tests indoors.
    Turret: (PTG)
    -50-55ft (15m+) with Whistlers
    -60ft+ (18m+) with Streamlines
    (ATG)
    -Probably looking at 70-80ft (22m+)

    Airgun: (PTG)
    -Typical 4B ranges - 40m quite easy with the right dart-barrel config
    (ATG)
    -Probably well over 200ft (~60m)

    I have no doubt that the turret could be pushed to 70ft or even 80ft (PTG) with the right springs, dart and barrel combo.

    And that's the end of my first proper write-up.
    Any comments, suggestions or questions(other than 'get a better camera')?


    Last edited by Johnnus on Thu Feb 14, 2013 2:07 am; edited 9 times in total (Reason for editing : Various bits and pieces)
    littlebro05
    littlebro05
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    Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE) Empty Re: Buzz Bee Berserker Internals & Overhaul (VERY PIC INTENSIVE)

    Post  littlebro05 Thu Sep 13, 2012 11:04 am

    The turret can actually get up to 80ft 15-25degree angle. :D.

    Epic write up. Directory it goes :D.

      Current date/time is Fri Dec 03, 2021 10:50 pm