Before I even started on anything costume related, I wanted to make Chewie's blaster, the Bowcaster!
After a bit of research, I found out this blaster is not very common, so finding examples was hard.
I'm not going to make a list of parts (if you want a list, just ask) but instead just show you what I did.
I worked only from photos and by a few (2) good examples of fan made bowcasters (from photos). The Photos are from the web and from the HD DVD screen captures.
Pattern applied to a simple piece of pine from Home Depot.
I blew this image up to a life size crossbow stock and printed it out.