Possible Solution for the Cheap Saber Conundrum

[cordaroyfog]

So I have had a lot of people ask (and seen posted on the boards),
"How can I make a cheap but cool saber?"

The answer is usually...this isn't a cheap hobby and there really isn't a good way to do it. I might have an idea that I am going to try.

It begins with this item:
Bayco LED Flashlight SLR-2380
Usually sells online for $15-$20

Possible total cost:
Flashlight $15-$20
New LED $8-$10
Blade/tip/etc ~$15

It's realistic that you could put together a decent looking, stable saber for ~$40 depending on what you needed exactly.


http://im1.shutterfly.com/media/47a0db30b3127ccefa429e9b020c00000050O02Acs2Lls5csQ e3nwQ/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

-Flashlight: 1 Watt (25 Lumens)
-Floodlight: 30 LEDs (60 Lumens)
-Rechargeable
-Impact resistant ABS case

Now the floodlight effect is very cool and can be left alone or maybe put a colored film on the inside of the plastic shield for color effect, I am aiming to replace the "flashlight" led which is white 1 watt to one more commonly used for sabers like a P4 White LED.

When we open the flashlight up (very easy to do just by removing 5 phillips-head screws. Here are pictures of the innards:
http://im1.shutterfly.com/media/47a0db30b3127ccefa436380e38d00000030O02Acs2Lls5csQ e3nwQ/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/
http://im1.shutterfly.com/media/47a0db30b3127ccefa4383cee3b300000030O02Acs2Lls5csQ e3nwQ/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/
I find that is is organized very well and laid out great.
Here is the connection for the single LED board which should not be hard to replace.
http://im1.shutterfly.com/media/47a0db30b3127ccefa43df19627a00000030O02Acs2Lls5csQ e3nwQ/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/
The nice thing about this is all the wiring for switch and charge port is already done! The button when pressed has 3 tiers.
1 Press - Flashlight only
2 Presses- Floodlights only
3 Presses - All Light
http://im1.shutterfly.com/media/47a0db30b3127ccefa4269b3c3f700000030O02Acs2Lls5csQ e3nwQ/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/
http://im1.shutterfly.com/media/47a0db30b3127ccefa42f07f83ef00000030O02Acs2Lls5csQ e3nwQ/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/
http://im1.shutterfly.com/media/47a0db30b3127ccefa43a027a3d300000030O02Acs2Lls5csQ e3nwQ/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/
http://im1.shutterfly.com/media/47a0db30b3127ccefa424d83c3d500000030O02Acs2Lls5csQ e3nwQ/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/
http://im1.shutterfly.com/media/47a0db30b3127ccefa43a204a3f100000030O02Acs2Lls5csQ e3nwQ/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/
http://im1.shutterfly.com/media/47a0db30b3127ccefa43583ba3b300000030O02Acs2Lls5csQ e3nwQ/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/
The width of the opening is 1.25" across, so finding a suitable blade holder shouldn't be that difficult.
http://im1.shutterfly.com/media/47a0db30b3127ccefa428d5dc36b00000030O02Acs2Lls5csQ e3nwQ/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Any other suggestions or ideas are welcome, will update with finished photos when done.

[cannibal869]

color film with something of a shroud over the floodlights might be a cool effect...

I suppose you could also loose the floodlights and wire in a hasbro board for sound, although
the startup sequence would be a little funky

[Crystal Chambers]

hmm...funny thing is I saw one of those flashlights just the other day and I wondered what might be in them and was amused by all the LEDs. Maybe some trans white blade material inside the window.

[DJMoonbass]

thats a good find bro!!!!

[jjshumpert]

ive got a tac light that im converting to a p4 for my daughter that would also make a cheap option, i think i gave 7 for the light which came with a star o. gutted it and had plenty of room for buckpuck, p4, custom heatsink, switch, trustfires and recharge plug... as soon as i finish milling out the end for the blade holder and tapping it ill post picks. granted tho its for my 10 yr old, the light is maybe 5 inches total, it fits in my hand with only about a quarter inch of the emitter end showing

[Crystal Chambers]

What about a lens/holder, heatsink and blade retention...possibly blade holder. I'd be worried about cracking the casing.