"We would be honored if you would join us" - Darth Vader
With those words Darth Vader got a handful of blaster bolts from Han Solo's signature DL-44 heavy blaster pistol. This prop was made from a replica German "Broomhandle" Mauser pistol manufactured by the Model Gun Corporation of Japan. This blaster is nearly identical to the DL-44 carried by Luke Skywalker. This version however, has added details on the side as seen in the photo above.
1896 German "Broomhandle" Mauser Replica from MGC (Model Gun Corporation)
The muzzles on these ESB version blasters were probably custom made based on the muzzle of Han's A New Hope blaster. A casting of the ANH blaster was modified for the stunt blasters used in Empire (and later in ROTJ). The ESB muzzles were made to fit snugly over the gun barrel allowing the tip to poke through the front. The front sight had to be filed off to do so.
Though it's long been believed that Han and Luke had very different muzzles, they were actually nearly identical- both had 3 knurled bands around the collar. The reason Han's seems different is because it was made much rougher and the knurled bands are misaligned and run close together in spots.
Luke's ESB Version Muzzle
On the side of the blaster, two piston halves from a Revell Visible V-8 Engine model were painted black and screwed in place with the open ends together. Phillips head screws were used. There are two small bits on either side where the pistons come together that have yet to be identified. They may be small rivets or screws.
Piston Half from Revell Visible V-8 Engine
Above the trigger are two small black rivets or screws. The small pieces underneath them are unidentified. Mounted over the square area toward the back of the Mauser is a piece from the Revell Visible V-8 model kit. This rectangular part is #98 from the battery box of the original motorized version of the kit. The word "Motor" is oriented toward the center of the gun.
Part #98 of the Revell Visible V-8 Engine
The scope mounted on the side is either a M19 or M32 brass azimuth telescope used by the military in many applications including tank periscopes. These were made in 1942 by Minneapolis Honeywell Regulator Co. (M.H.R.). We believe the M19 is the more likely scope used and it was attached with the original hex head bolts.
M19 Telescope, 1942 M.H.R. Co. with bolts
The scope mounting bracket was probably custom made of 1/8" thick angled aluminum and was attached with some sort of round fastener (approx. 3/4" diameter). A black spacer approximately 3/4" diameter and 1/8" thick was used between the scope bracket and the gun body..
You can see what the other side of this prop looks like on the BlasTech DL-44 Luke Skywalker version page.