I use "Art Aslyum" Toy shells and value add my "art" to them (aka I avoid the copyright problems and replace all but the shell). This build was based on the images of a phaser from a 1996 auction. It included a three watt laser as requested by the client. I built two, it hardly takes more time to knock out two vrs. one. The extra was eventually sold to another collector. All the trims are metal. The flashlight nozzle version, aka the second build, had all the metal made by me at my shop. To get the right heft and stiffness I epoxy 5/32" diameter brass rods inside the shell wherever I can. I also use a big C360 copper alloy internal heat sink that adds a lot of weight. I'm going to post the "how to clean the shell pics" next. After that "battery access without a butt cap or any screws".
Pictures: B&W 1966 Phaser with Laser
Video: B&W 1966 on YouTube