Jay-gon Jinn's Chrome Saber 25(Seoul P4, w/illuminated AV switch, non-sound stunt)

[Jay-gon Jinn]

This will cover the complete build of Chrome Saber 25 (CS-25) from start to finish. I'll be using a simple non-sound resistored set-up for this saber, and will be cutting a chrome sink tube sleeve for it.

Here's the basic render:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/SaberBuilder_render-MasterIstari-3.png

The Parts:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6487.jpg

Parts list:
MHS blade holder style 12
MHS ribbed extension; powder coated in RIB3 style
MHS hilt style 2 w/guarded switch hole; powder coated in SH22 style
MHS pommel style 1
7" chrome sinktube; 1 1/2" O.D.
Machined covertec button; black anodized
8-32 x 1/4" socket head cap screw
illuminated anti-vandal switch w/blue ring; 12v led (not from TCSS)
Machined bezel for anti-vandal switch
4 AA (6v) battery pack
Seoul P4 blue led
5 degree lens
Luxeon III lens holder
3.3ohm, 3watt resistor
quick-disconnect plug

This saber shouldn't take too much too long to build! I got started on it yesterday by cutting the chrome sink tube to length, and as soon as I cut it, I realized I had goofed....I measured it wrong so it was un-useable. I had wait until today to go to the hardware and get a replacement for it.

So, after screwing up the first chrome tube I cut for the half sleeve for this saber (I measured it at 6" instead of 7"....D'OH! :roll: ) I cut the new one to length and used my rotary tool to de-burr the part:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6595.jpg

With the sleeve deburred, I laid it out next to the hilt and checked to see where I'll have to cut it for the grip window:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6596.jpg

I then marked it off using a black Sharpie:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6597.jpg

And using masking tape, made the pattern I'll follow with the cutting disc on my rotary tool:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6598.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6599.jpg

I set it up in my drill press's vise:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6600.jpg

And started cutting:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6601.jpg

I always follow the direction of the cutting wheel, so in this case, I had to move from right to left to make these cuts:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6602.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6603.jpg

To remove the un-needed piece, I'll cut across the corners at an angle:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6604.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6605.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6606.jpg
The black thing in the corner of this picture is the end of my shop vac's hose:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6607.jpg
I use it as a dust collector when I'm cutting tubing....helps keep the mess to a minimum, and I breathe less dust that way. I also use a dust mask and safety glasses, as well. ;)

There's more material to remove from the corners, so I'll continue with the cutting disc on the rotary tool, and just get what I can with it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6608.jpg

Done with the cutting disc:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6609.jpg

I'll change the disc out for the 5/8" sanding drum attachment so I can round out the corners:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6610.jpg

I use an oscillating motion when I do this, to even the wear on the sanding drum. Otherwise, I'd get a single worn strip on the drum, and eventually a cut. Work the drum into the corner until all the material is removed, and you have a nice rounded corner:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6612.jpg

I did all four corners:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6613.jpg

To further straighten the edges of the window, I'll use a hand file for metal:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6614.jpg
This may require the removal of extra material depending on how steady your hands are when you cut the window out, and how straight your cuts were. I had to go back to the rotary tool with the sanding drum to even the corners out again after I was finished filing.

With the filing done, and all the edges looked straight, I went over the widow's edges again by hand with some 400 grit sandpaper:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6615.jpg
After that, I went over it again with a piece of 800 to really smooth it out.

Here's the finished sleeve with the hilt section:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6616.jpg

And test fit:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6617.jpg
That'll work!

[Tava]

I like how you did the rounded corners.

[Matt Thorn]

Great tutorial, Jay-gon. Now it seems kind of odd that no one (to the best of my knowledge) ever posted a tutorial on basic dremel work before, although you have touched on the subject in some past build logs.

When you say "follow the direction of the cutting wheel", do mean the direction in which the wheel "pulls"? Looking at the top of dremel, the wheel spins clockwise, right? So it wants to pull to the left, no? Is that what you mean? I've been dremeling for three years now, and I was never sure whether it was best to go with the pull or against it. I guess the answer is "go with the pull." Please correct me if I've misinterpreted you.

Thanks!

[Jay-gon Jinn]

Great tutorial, Jay-gon. Now it seems kind of odd that no one (to the best of my knowledge) ever posted a tutorial on basic dremel work before, although you have touched on the subject in some past build logs.

When you say "follow the direction of the cutting wheel", do mean the direction in which the wheel "pulls"? Looking at the top of dremel, the wheel spins clockwise, right? So it wants to pull to the left, no? Is that what you mean? I've been dremeling for three years now, and I was never sure whether it was best to go with the pull or against it. I guess the answer is "go with the pull." Please correct me if I've misinterpreted you.

Thanks!

I try to go with the pull, Matt...let it go in the direction it wants to go.


I did a test assembly, and there is one little problem/issue that will need to be addressed:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6619.jpg
As usual with this particular blade holder, it is way off center from the switch hole in the hilt.

There's two ways I can fix this, one being much easier for me to do, and the other will take a bit of time to get right.

The first way to correct this issue would be for me to rotate the sleeve on the hilt until it is centered with the top of the blade holder, and drill a new switch hole. Problem solved.

The other thing I can do is try to drill a matching hole in the sleeve so it fits with the hilt, then try to sand down the bottom of the blade holder, the top of the ribbed extension, and the top of the hilt to get the parts to screw together a little further so that everything lines up.

I think I'll take the easy route, and just drill a new hole for the switch.

I re-aligned the sleeve on the hilt, and got ready to drill a new switch hole:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6626.jpg
That looks good.....now to set it up in the drill press!

All set, and drilled:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6627.jpg
When drilling for a hole as large as the 5/8" one required for the illuminated switches, I like to start with a smaller one first. This is a 3/8" hole, and is lined up almost perfectly with the center line of the blade holder. I think it'll do:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6628.jpg

Now to drill for the BIG hole:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6629.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6631.jpg
Done!

Oh, and one thing to keep in mind when lining up parts for drilling holes is to make sure you have the copper heatsink installed in the saber first:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6632.jpg
Otherwise, you'll drill the hole off-center and it just won't look right.

Now to de-burr the hole, on both the outside and inside:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6633.jpg

and check the fit:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6634.jpg

I installed the switch temporarily, and set up to drill and tap for the CT button:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6635.jpg
The hilt is centered in the vise, but I'll have to eye-ball the alignment with the switch....I want the CT button to line up in the same center line.

With it right where I thought it looked lined up, and using a #29 drill bit, I drilled the hole:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6636.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6637.jpg

Tapped it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6638.jpg

Installed the CT button:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6639.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6640.jpg
I think I got it right.....

Yup, I got it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6641.jpg

Now I'm thinking there isn't enough chrome on this saber.....
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6642.jpg
This section needs something.....

This?
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6643.jpg

Or maybe this?
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6644.jpg

Maybe something that will match the angle?
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6646.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6647.jpg

I kind of like this last idea:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6648.jpg

Whatever I add will be epoxied to the top of the ribbed section, making it easier to install the blade holder if an led swap is performed.

[Jay-gon Jinn]

I decided on the last option, so I mixed up some 2-part epoxy last night, and installed the chrome ring on the ribbed extension, and let it set up overnight.

Today, I masked off the emitter and drilled and tapped it for an attachment screw:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6652.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6653.jpg

Next, I flipped it over, changed the drill bit and drilled and tapped for the 10-32 thumbscrew:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6654.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6655.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6656.jpg
The reason I drilled and tapped for a mounting screw on the emitter shroud is pretty simple. I wanted it to be removeable for polishing the aluminum emitter underneath the shroud. It can be a real pain to get up under the edge of the shroud, so it's better to be able to remove it and re-install it.

Now to decide on what pommel is going to go on this one....I have a left over powder coated style 3v2 from CS-24:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6657.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6658.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6659.jpg
I'm still not sure I like this pommel with the style 12 blade holder....

I also have a plain one:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6660.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6661.jpg

Or, I have a style 3v1, which is also plain:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6662.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6663.jpg

But I also have a style 8:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6664.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6665.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6666.jpg
This one makes it look a little too long....

Or, I could do what I did on CS-24 and get a style 4:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6667.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6668.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6669.jpg
That's not too bad.....

Here's the pommel I ordered with the rest of the parts, a style 1 for a guarded switch:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6670.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6671.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6672.jpg
I kind of like the shorter pommels on this one, and I did have an idea of how to utilize the hole in this one:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6673.jpg
I think you can guess where this is going.....;)

[Jay-gon Jinn]

I worked on the crystal pommel a bit yesterday afternoon before going to work...this is what I got done:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6674.jpg
I marked the locations I'll need to to drill for the 4-40 screws. I used the MPS insert as a pattern.

The crystal will sit in there like this:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6675.jpg

And then, the insert will cover it up and secure it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6676.jpg

The plan is to have the led right up close to the crystal like so:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6677.jpg

The led will be located on the end of the battery pack like this:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6679.jpg

Hopefully, this will fit together like this in the saber:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6678.jpg

The first thing I had to was drill for the screws:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6680.jpg
This was fun trying to keep a rounded pommel straight and level in the vise.... ::)

One of the holes was a little off because of that and went through the recessed area for the switch:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6681.jpg
You can just barely see the little hole in this picture....well, I can't let that stop me, I've gone this far with it....

I checked the fit of the crystal:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6682.jpg
Hmmm....not quite going to fit....only two screws can go in like this....I'll modify the crystal then:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6683.jpg

It still needs a little work to get the crystal in there, and the insert to fit straight, but I think this'll work:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6684.jpg

[Shadar Al'Niende]

I thought of wiring the accent through the battery pack like that, if you could post some pictures on how you wire it i would be most grateful!

[Jay-gon Jinn]

There will be pictures of the accent led wiring, Shadar, fear not! ;)

Here's the finished pommel/crystal chamber:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6685.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6685.jpg)

Yes, it does look cool....the question is, though, will it light up?

I soldered the led to a 2-AA battery pack to find out:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6686.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6686.jpg)

Then held it up close to the crystal in the pommel:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6687.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6687.jpg)

Yup, I think it'll work....

[Et Kin Evenstar]

Keep 'em coming Jay! I learn more from one of your posts then reading through dozens of others. Not to mention your work is beautiful.

[Jay-gon Jinn]

I started on the wiring of the saber by assembling the led and the battery pack....to start, I had to solder a resistor to the led:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6688.jpg
In this case, since I'm using a 6 volt battery supply, and the led spec's at 3.2v, 20 ma., I'll use a 150 ohm, 1/8watt resistor. I determined this using this online calculator:
http://led.linear1.org/1led.wiz
Bookmark it! It comes in handy! ;)

I'll need to determine the length of wire needed to reach from the led to the switch, so I laid it out the parts on the bench:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6689.jpg
I think the battery holder's leads are going to be just short....I'll have add to them later.

I decided I'll use yellow wire for the positive on the accent led, and then green for the negative. This is 26ga. wire, and will thread into the battery holder alongside the battery leads. I did the positive wire first:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6690.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6691.jpg

I pre-tinned the wire, and slid on some heat shrink;
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6692.jpg

and soldered the wire to the led:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6693.jpg

I did the same to the green negative lead:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6694.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6695.jpg

And then pulled the excess wire back through the holder, snugging up the led:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6696.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6698.jpg

I left the wire for the pommel led on the spools as I was soldering them to the led, and to figure out where to cut them off, again, I laid the pack next to the hilt to see how much wire I'd need:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6699.jpg
I then cut the wires off.

Now I need to come up with a way to ensure the battery pack stays in place and is properly lined up:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6700.jpg
I found this piece of 1" pvc that I had previously cut for something else (I usually use these to mount speakers) and thought I'd try it out and see if it'll work:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6701.jpg
We'll come back to that in a minute or two....I need to make the wires into a harness, so I added a piece of heat shrink tubing to the battery pack:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6702.jpg
And then I added a couple of pieces further down the wires:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6703.jpg
That should just about do it for the battery harness.

Next, I hot glued the pvc ring to the battery pack, and checked the fit in the hilt....it didn't quite work out the way I'd hoped....the screws on the crystal chamber caught on the glue, and spun the battery pack as I screwed on the pommel:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6705.jpg
Alright, that's not going to work.

I looked through my parts drawers and found this, though:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6706.jpg

I'll have to modify it to allow the led to pass through closer to the center, though:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6707.jpg

After re-doing the wiring harness, and gluing the speaker mount to the battery pack, I think it's going to work:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6708.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6709.jpg

It fits into the saber just like usual:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6710.jpg

To ensure this will work before I assemble the saber, I'll wire up the 2-AA battery pack to the led's leads again:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6711.jpg

Added the batteries:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6712.jpg

And then the pommel:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6713.jpg
Yeah....looks good!

Now I can start on the rest of the wiring and assembly!

[Jay-gon Jinn]

With the pommel all set, I began the wiring for the switch...this is pretty straight forward, but might get a bit tricky....I started by pulling the wires from the battery pack up into the hilt, and then sliding the switch nut over the wires:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6714.jpg

I then fed the wires through the switch hole:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6715.jpg


I pulled them out a little further so I can work on the switch easier, and then made up the main blade led connector, as well:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6716.jpg

I had to feed those wires up through the nut:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6717.jpg

Next, I soldered all of the negatives to the negative post for the switch led:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6719.jpg
These all need to be connected as they all have a common ground. The switch will be interrupting the positive side of the circuit.

Then I started on the positives:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6720.jpg
These are the positives for the led's. I attached them to the NC tab....with the ring style switches, I like to have them wired for the button to be "up" when on, since they light up better that way. This particular switch has a 12v led inside, so it is not necessary to use a resistor for it, either. I had these soldered to what I figured were the wrong terminals, though, and changed it after taking the pictures. I wound up soldering the battery positive to the Common terminal by itself, and then soldered the accent led's positive to the NC terminal with the main blade led's positive.

I thought about soldering a simple jumper wire from the switch led positive tab to the NC tab, but eventually changed my mind:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6721.jpg

Instead, I decided to cut into the main led positive and make a "Y" connection to power the switch led from:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6722.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6723.jpg

I added heat shrink tubing to the connection, but didn't shrink it...better test everything first:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6724.jpg
Well, It works! Sort of....when I pushed the button to turn it off, the mechanism that latches the button down BROKE!!!! The switch essentially became a momentary and was unusable!

I looked in my parts drawer to see if I had another latching blue ring button and found none.....just latching w/green rings....and one latching blue dot:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6725.jpg

I soldered it up just like the first switch:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6726.jpg

And tested:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6727.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6728.jpg
I think I like the blue dot better...it's brighter than the ring type was!

Now to assemble it......stay tuned!

[Jay-gon Jinn]

I added the ribbed extension:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6733.jpg
And remembered I still had to mount the led to the heat sink and solder the male end of the connector to it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6734.jpg
I put a thermal heat transfer pad underneath the led, screwed it to the heat sink, and soldered the connector, plugged it in and tested:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6735.jpg

I slid the heat sink into place in the top of the ribbed extension:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6736.jpg

Grabbed a 5 degree lens and a Lux III style holder:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6737.jpg

Snapped the 5 degree lens into the holder:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6738.jpg

Set it in place on the led:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6739.jpg

Lastly, I installed the emitter:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6740.jpg

A couple of shots of the saber:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6741.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6742.jpg

Popped in the blade:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6743.jpg

This particular blade has the TCSS "bullet" tip:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6744.jpg

So, with that, this saber is just about finished....one thing remains....I need to cut down the blade thumbscrew a bit, because it's too long and sticks out like a sore thumb when the blade is inserted, and then it's on to FINAL PICS and a VIDEO!

[Sidd]

Master Jay-gon how is it you are able to get the whole blade tip to light up like that? it looks awesome. I love the whole saber

[Crystal Chambers]

Sweet saber and an awesome tutorial!

Looks like enough space left that it could easily be upgraded for sound too. I look forward to seeing more pics and the video.

[cardcollector]

Master Jay-gon how is it you are able to get the whole blade tip to light up like that? it looks awesome. I love the whole saber

I second that question! I can't figure out how to do that... (and I've ruined 2 experimenting....)

You tutorial/build log/gallery is truly incredible!
Thank you so much for the time you put into these posts.

[Jay-gon Jinn]

Master Jay-gon how is it you are able to get the whole blade tip to light up like that? it looks awesome. I love the whole saber
Trade secret, so if I told you, then I'd have to.....well, you know how that goes.....;)

[Crystal Chambers]

Trade secret, so if I told you, then I'd have to.....well, you know how that goes.....;)


Unless you have a unique method it's not a heavily guarded secret...

Blade tip solutions have been discussed just use the search-fu.

[Shadar Al'Niende]

Taking off some small areas of reflective surface will allow a small amount of light to pass through. Usually a small hole in the center, or a few spaced around the area should suffice.

Remember, less is more. You can always take more off, you cannot however....put more back on ;)

[Jay-gon Jinn]

Unless you have a unique method it's not a heavily guarded secret...

Blade tip solutions have been discussed just use the search-fu.
wow...can't a guy have a little fun on these forums anymore? Sheesh....

[Crystal Chambers]

And now a double post Jay-gon? hehe With all that you've shared I think you're entitled to keep a few secrets.

I have some extra tips and mirrors I've been meaning to test out but that's last on my priority list. When I get a chance I wanna try using a smaller mirror so I don't get any bright spots in my tip. I've seen people drill a hole in the middle and it doesn't look good IMO.

[Jay-gon Jinn]

Oops...hit "quote" instead of "modify"....I don't drill a hole in the mirror or the tip, either. :)

[Jay-gon Jinn]

Okay, time for


FINAL PICTURES!!!
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6745.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6746.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6747.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6748.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6749.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6750.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6751.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6752.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6753.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6754.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6755.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6762.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6763.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6757.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6758.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6759.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6760.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2025/100_6761.jpg


Video to come as soon as I can get the family to quiet down long enough to shoot one...:rolls:

[Sidd]

Thats a fantastic hilt Jay-gon it looks like its right out of the LFL archives but better.


whats the over all length of that hilt? its looks to bee about 11-12 inches if i were to guess

[Crystal Chambers]

And the blade for that matter...looks like one long blade.

[Jay-gon Jinn]

Thats a fantastic hilt Jay-gon it looks like its right out of the LFL archives but better.


whats the over all length of that hilt? its looks to bee about 11-12 inches if i were to guess

It's a bit over 13"...I'll have to measure it to get an exact measurement.

[Sidd]

I would bet the blade is about 30 inches out of the hilt, it looks similar in length to my blade.

the longer blades look a lot more elegant i think

[Crystal Chambers]

Sidd I think you're way off. I use 32" total myself. If the hilt is roughly 13" then the blade looks like 36" or even longer.

[Jay-gon Jinn]

The blade is 36"....37" with the tip, so 35" total exposed length.....the hilt itself is 13 7/8".

[Jay-gon Jinn]

Video Review:
http://www.youtube.com/watch?v=8R1yH8dPxaM

[Kal El Rah]

Another great looking saber Jay. I know hez loving it! ;):cool::-P

[cardcollector]

there are many pictures missing on page 2...:(:(

are they gone for good?

[Jay-gon Jinn]

there are many pictures missing on page 2...:(:(

are they gone for good?
Nope, just had to move them from my default PB album to the correct one...it's what happens when I upload pictures at 2:00 a.m..

[cardcollector]

2am huh, gee whiz, I can hardly upload pictures around 2pm!;)

Well, I'm glad they are back now...:cool:

[Garek Telgan]

Ok, I did a quick search for the answer to this question, but various keywords for cutting a thumbscrew are hard to come by. Can you just cut it off and not worry about any burrs or the threads getting messed up? I've never tried to shorten a screw before.

[Shadar Al'Niende]

You would need to cut it, and then file/deburr the screw to make sure it doesn't "bite" into your part, and that your threads are ok. (just cut it fairly straight and make sure you clean it up, you should be fine.)

[Jedi-Loreen]

You can also put a nut on it before you cut it, if you have the right size, that helps clean up the threads then you take it off. But definitely make sure your threads and the end of the screw are smooth and burr free.

If your screw end isn't smooth, it'll gouge into the blade, of your threads have burrs, they can cause the screw to get jammed into the threads in the blade holder.