What about using one or two of these type of check valves?
http://www.usplastic.com/catalog/item.a ... id=redirec
Looks like I could get them as low as $.60 each plus shipping due to the qty discount. I don't know the required specs for PSI for this...seems like 150PSI is quite a bit. If I could get away with just using 1 and accept the nozzle leaking that would save even more $$, I just can't picture how to do that. I think it would be fine, they leaked out the nose last year too - the boys got the hang of quickly tipping it up to fire with no problem.
I can see how it would need 2 check valves, in order to create the vacuum that draws the water in and in turn forces the water out - just not sure how to fully implement that functionality yet. If we start from last year's design, I can see the 2 check valve system, but I can't picture in my mind how a single check valve system would work. I roughed up this design this morning. I'm estimating that we're at $3.44 per kid - probably slightly less, but I don't know how to attach that water bottle, nor do I know if this will work. Can I get your thoughts on it?
Forgive that things are not to size, I can't figure out how to resize the 2 longer pipes up front to appear 20" each in the PVC Designer software. The handle and smaller piece at the rear are estimated at 5" each. I'm concerned there's too much empty space inside the gun, though maybe that's resolved on the first pump or so, when the entire system is filled. It seems the more efficient design would have the 2 check valves closer together but I can't figure out how to implement that successfully (and in budget). last year's gun had a cork there. I don't know what we could use to plug that hole and hold a check valve. We were talking about using a rubber washer/gasket sandwiched between 2 metal washers this year (like in the instructables I listed originally) to plug that hole (screwed into "something"), because the #5 corks we used last year blew up into the handles of some of the guns. A #6 cork might fix that but I'm not sure if we could drill a hole thru a cork, glue in a check valve and expect that to stay in place. I figured moving the check valve all the way to the rear might fix all of that and save some cost since we're already well over budget on this. But there's a definite cool factor to what we're doing, sometimes it's worth going over on 1 activity just to blow their minds. And of course getting it down to a single valve system would be even better, cost-wise. There's also some question in my mind as to how to attach the check valves....right now all I can see doing is drilling holes for the barbs to stick through the end caps and somehow gluing them in place. (?)
We may be able to use the water bottle squirt guns that you squeeze as well, I'd have to run the numbers to see how cheap we can get that down to. What often happens is that their daily projects get taken home (or the chaperons tell them to take them home 'cause they're tired of getting squirted lol) so each day we try to do something different.
We're not setting it up as a competition style event, since that mandates a winner and loser. Boys in this age range still get very emotional over these things, tears and all. We want all of them to have fun, even the kid that couldn't hit the broad side of a barn.

We'll probably setup targets for them to shoot at and let their imaginations take over. Also we are not allowed to design an activity that says go fire at each other - some kids don't like to get squirted, but of course boys will be boys and in the end, they'll all end up cooling each other off, whether from splatter/over spray or just silliness. (they always end up squirting each other anyway, we just can't tell them to)
Thanks for all of the advice and suggestions ya'll! Keep it coming!
Andrea