This is my first saber, built using a board from a 1999 Hasbro Electronic Qui-Gon Jinn Lightsaber. It has a charger port (a Canon 2.1mm). The outer body is a 38mm (1.5") sink tube, and the inner body is the same, cut down the middle and "squished" to fit inside, and covered with a thin sheet of copper. The switch is a guarded momentary switch identical to the one sold at TCSS, the battery pack is 4 AAA Ni-MH batteries, and the speaker is one I found at a local electronics shop. The LED is a Luxeon III. The blade holder is a TCSS Style 3. The grip strips are something I found at my local hardware store and used as-is. There's no pommel. When I cut the pipe, the cutter "pinched" the cut edge just enough so that the 36mm strainer I used as a speaker grille wouldn't slip out. I just glued the grille to the film case that houses the battery pack and speaker.
Not bad for a first try, huh?
(Note that photos are in reverse chronological order.)
Major shock: the MHS adapter and blade holder won't fit in the hilt! The inner diameter of the Japanese 38mm pipe I bought is just 0.5mm or so too narrow.
So close, yet so far.
Update: Problem solved, if not elegantly. I made a vertical cut at the top of the underside, trying to make it seem like part of the design. I had a hell of a time getting the MHS adapter in, but it's in. Now if anything goes wrong with the inner electronics, I'm in for a struggle.
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