| The stefan dart, originally designed and built by Stefan of Nerf
Complete, is an amazing work of art. They cost about $.05
per dart, and they are more durable and shoot farther than
Nerf's darts. This page contains info on the process I use to
create my darts.
The Materials
I use what Stefan uses, a substance sometimes called Foam
backer rod. Or at least, that's what it is in Canada. Here where
I live, it's called "caulk saver." It's a foam
cylinder usually sold in lengths of about 20 feet. The 5/8"
diameter is what you need for megas, and 1/2" diameter
works for micros.
Here's a bag of it.
I also use 3/0 weight fishing sinkers, bought at the local
Wal-mart. And, of course, hot glue.
The Construction
I section the foam into 3" or 1.5" sections.
Sometimes I go 2" for micros, for use in the Powerclip. I
use a marker that won't wash off to mark the foam in the correct
places. Then, I cut the foam every four darts. So I have a bunch
of little stick of foam that are four darts long. I take them in
the bathroom. I get out the hairdryer and turn it on. What you
do is hold the foam in front of the hairdryer and make it
straight. Do this next to a sink, because you'll want to put the
sections in cold water to harden them once they have been
straightened. I straighten all of them then take them back to
the workshop.
Next, I put holes in. I use the hot glue gun because it's hot
enough to melt the foam and make holes. I use one of the little
small hot glue guns that you can buy at Wal-mart for $2. I make
a hole in the back of the dart (unless it's a 1.5" dart, in
which case I make no hole in the back) as big as the nozzle of
the glue gun. In the front, I make a hole just big enough for
the fishing sinker. I put the sinker in and put hot glue over
it.
On the subject of holes in the backs of darts. There was a
discussion of this at NerfOnline.
Some people said the holes didn't matter except to fit over the
poles in most Nerf gun barrels, but some said it improved the
range of the gun by forming a "pocket" of air behind
the dart. I figure, it costs me nothing to put a hole in the
back, so why not? If anyone knows the physics behind this,
please tell me about it.
Darts. From left to right: a micro stefan, a 1.5" 5/8"
stefan, another 1.5" 5/8" stefan, two 3"
5/8" stefans, a supermaxx, and a mega.
Details of holes. My 3" stefans have holes about the size
of those in supermaxxes.
The 1.5" stefans are for use in guns with short barrels,
such as the splitfire.
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