I actually have tried this exact thing. My extended family has rebuilt clasic cars for as long as I can remember. So I have some experience with fiberglass resin's for auto-body sculpting. Last summer I took some angle steel and bent it into a rudimentary shape of a rifle to use as the main support/action framing. Then I used fiberglass screening and resin to pour & shape my own stock. It was quite fun, and a TON of work. However, the end product was far from usable. It was no doubt strong, as it weighed close to 20 LBS. Fiberglass is heavy as all sin but I'm sure the steel frame didn't help. The other thing is... fiberglass, as strong as it is, does not have the greatest "shock" resistance. So with all the recoil, you can expect it to crack. However, I believe this can easily be done using the proper materials....
If I did it over again, I would use some sort of polypropelene, or metal based plastic resin. There are literally dozens of companies that produce plastic resins for movie sets... you know for building a 2000 lb boulder that actually only weights 10 lbs. They make all sorts of consistencies and strengths. There are some plastic foam and/or resins that can hold an adult males weight on them and still be incredibly light. With that in mind... I would take some scrap 2x4's of pine or a solid 4x4. Using a band saw, belt sander, router and hand file, I think I would make a very rough shape of the stock I am trying to build. Use that as the base for creating a mold... then once the mold is made, you can pour a solid reinforced polypropelene rifle stock. Router out the channel for the action and barrel, and have a milled block of aluminum set down for the action.
It is certainly doable, and with the right effort and patience it can defintely be done. But the question is... for all that effort, time and money (expect at least $150-200 in cost)... would you still want to build one? or just buy one?
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