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Luke-SkyMarcher
10-09-2010, 02:42 PM
Ok, I figured it was high time I posted a progress thread for one of my sabers. When it is finished, this will have been the third saber I machined from scratch.

This is a saber a kid commissioned me to make. We did a lot of back-and-forth on the design, to get the cost to where he could afford it, and still have a design he liked. This is what we came up with:

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/RenderFinal7.png

Though, at the last minute, he decided to change the blade color to red; I think it fits this hilt design better.

While I don't care much for the design myself, there are a few challenging design elements to make things interesting to build, most specifically the claws.

The claws were based on the old MHS claw style 2. I decided to make them out of 1/4" aluminum plate. First, I drew the template.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3317.jpg

Then, I made copies and attached them to the aluminum plate.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3318.jpg

I used a table saw with a metal cutting blade to do the rough cutting.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3320.jpg

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3321.jpg

At this point, I had the other parts of the saber machined to this point: (I hadn't taken any progress pics previous to that)

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3319.jpg

After I did the rough cut for the claws, the templates were so mutilated, I decided to remove them entirely and make new copies.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3322.jpg

About simultaneously with this, I machined the blade holder.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3323.jpg

Here it is with the other pieces again.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3324.jpg

The pommel was next:

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3325.jpg

----Side note------

I did some work for the "guts" around this point; I wanted to try my hand at the "make your own driver" project, and this seemed an ideal project to do it with. I also wanted to do some really basic chassis with washers and threaded rod.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3369.jpg

----/Side note------

I ended up using the mill to get the claws to shape; it was actually easier than I thought it would be.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3376.jpg

After doing each claw individually, I took off the templates and lined them up, and re-did all the sides, just enough to make sure they were as close to identical as I could get them.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3377.jpg

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3380.jpg

Here they are after being cleaned up a bit.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3381.jpg

The part that caused a bit more concern was the attachment of the claws to the emitter. From all my previous experience, I knew that drilling (much less milling!) on a cylinder can be very difficult to get just how you want it. Getting four milled slots exactly lined up and perpendicular looked to be pretty much impossible.
After researching, I found the solution; a spin index. Trouble is, the largest stock this fairly inexpensive "spindex" could hold was 1 1/8"... so I machined an adapter so it could hold the blade holder. After setting it up, actually milling the slots was cake - and they came out pretty nicely.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3382.jpg

While the part was still in the spindex, I moved it to the drill press, and drilled the holes for the mounting of the claws - clear through the claws and into the blade holder, to make sure the holes all lined up.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3384.jpg

While I had the opportunity, I figured I might as well do the blade screw as well, exactly halfway between two of the milled slots.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3386.jpg

While it was still mounted in the spindex, I tapped the holes. I also counter-bored the holes in the claws. Then I did a test fit to see how it all came together:

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3387.jpg

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3388.jpg

Bringing it back to the saber, this is how it looks:

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3389.jpg

After drilling and tapping the rest of the holes to hold it together, and doing some more clean up, here are some final pictures before powder coating.

Parts:
http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3393.jpg

Saber:

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3394.jpg

Rafalema
10-09-2010, 03:13 PM
Awesome.

Just plain awesome.

Lord Dottore Matto
10-09-2010, 03:22 PM
So far so good man!

ARKM
10-09-2010, 03:30 PM
Lookin' good.

jin starkiller
10-09-2010, 04:43 PM
lookin good

cardcollector
10-09-2010, 04:49 PM
Its good to see you are still making Sabers.I don't care for the design much, but look forward to seeing the build process!:cool:

equinox13
10-09-2010, 05:42 PM
excellent design. i'm rather fond of the angular look of the claws. i look forward to seeing more pictures of this build! ^_^

Et Kin Evenstar
10-09-2010, 06:02 PM
Fantastic. Can't wait to see it all finished.

vargose
10-09-2010, 08:10 PM
"make your own driver"?
Did you make the plans for it, or get them from somewhere else? Is it a constant current driver? I am definitely curious.

cannibal869
10-09-2010, 08:12 PM
nice machining skillz!

Nice job so far

Skottsaber
10-10-2010, 05:23 AM
Did you make the plans for it, or get them from somewhere else? Is it a constant current driver? I am definitely curious.

As am I.
Awesome work!

Luke-SkyMarcher
10-10-2010, 11:09 AM
Its good to see you are still making Sabers.I don't care for the design much, but look forward to seeing the build process!:cool:

Yeah, the design's not really my favorite either, but the customer likes it, and I guess that's the important thing. ;)


"make your own driver"?
Did you make the plans for it, or get them from somewhere else? Is it a constant current driver? I am definitely curious.


As am I.
Awesome work!

I did not make the plans... they're over on the FX saber forums, with all the necessary details. ;)


Thanks for the encouragement, guys. I hope to do some of the powder coating this afternoon.

Luke

Invisas1979
10-10-2010, 01:17 PM
Good work man, not easy to do this sort of thing from scratch.

Personally I think the pommel is a bit safe, but I understand the young man had a budget.

I'd maybe loose the clamp for this saber, or move it up to the claws and have another single claw type going down beyond the bottom of the pommel.

Give it some egde.

Luke-SkyMarcher
10-10-2010, 04:35 PM
Thanks for the design advice, I do appreciate it - it helps me know how I can improve.



Well, I did the powder coating, so here are some more pictures for your enjoyment.

The parts hot out of the oven (literally!)

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3397.jpg

I also cleaned up the end of the emitter, and put the saber together. This is the first time where it really "felt" like a lightsaber to me - especially something a sith might carry.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3398.jpg

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3401.jpg

Ronan
10-10-2010, 04:53 PM
Nice! I have seen this design before... hmnnn maybe the designer shared it on TCSS in the shoutbox...

jin starkiller
10-10-2010, 05:12 PM
lookin good their can't wait to see it finished

Caine Drathul
10-13-2010, 10:38 PM
I am supremely impressed! Awesome job, dude.

Mind-gon Ohnobi
10-15-2010, 09:36 PM
Nice little lathe/mill combo. I miss having access to machine tools at work!

Luke-SkyMarcher
11-09-2010, 07:49 PM
Well, here is the long-awaited update

I had a very difficult time with the powder coat of the main hilt section. I machined out the grooves, but it left burrs which destroyed some of the powder coat, so I coated again... the cycle repeated several times. I ended up getting some heat-resistant tape (thanks for the pointer, Wade) and masking off the areas I had machined, in order to clean off the messy spots. Here it is, masked and ready to go:

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3427.jpg

Here it is after coating, having removed the tape and cleaned it up a little bit.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3432.jpg

I've also been working on the electronics; the chassis here is simply for the purpose of function, as I'm hoping no one will have to take this saber apart after I finish it. :D It has helped a lot in keeping things well organized, as does color-coding the wiring.

http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3435.jpg

By the way, the sound board is from the older "build-your-own lightsaber" kit, running with a transistor setup.

I'm hoping to finish this one soon; just a little soldering, a little gluing, and some cram-fu left!

Luke

Crystal Chambers
11-10-2010, 05:38 AM
Very Nice! The last pic with the lathed rings looks very good. I anticipate you'll out do the design on this. Looking forward to seeing it complete. I hope the sound does it justice...maybe it will need a sound upgrade later.

cardcollector
11-10-2010, 08:27 AM
Lookin' good Luke! That is some impressive PC. :cool:

TheSithStalker
01-30-2011, 01:22 AM
I'm new to the group. But, first and most importantly, I would like to say the work on this lightsaber is truly great. I was also wondering what would something like this cost to make if it was streamlined like this.

http://i1220.photobucket.com/albums/dd460/master_sith_stalker/SithLightsaber.png

Rafalema
01-30-2011, 02:29 AM
Please read the forum rules. You broke 2 of them with your post.

1. Necropost (Reviving old threads for not much of a reason)
2. Soliciting (This forum is attached to a store. You want to do that saber, order some MHS parts and cut the claws yourself like Luke here did.)

Welcome to the forums!

Thanks!

eastern57
01-30-2011, 03:36 AM
Thanks for the correction, Rafalema. ;)

TheSithStalker, Luke SkyMarcher has an account at FX-Sabers, please take any business prospects over there. Thank you.

Luke-SkyMarcher
01-30-2011, 05:58 AM
Sithstalker -

Thanks for the compliment on the saber. As to the necroposting, I wouldn't worry about that too much as I was about to resurrect the thread myself - since I finally finished this saber. Pics will probably be going up later today.

If you're asking how much it would cost for you to make (and that is what I would suggest), It's really hard to say without knowing a lot of other factors. If you're asking how much it would cost for me to make it for you, well, that, as Rafalma said, is not allowed on this forum. I might be inclined to decline to take on the project anyway - I barely have any time to do this anymore - Engineering school keeps you very, very busy.

EDIT: I now have the pics for you guys.....

I don't know if I gave the specs before, but this saber has:
LEDEngin 5W Redr
Custom Constant Current Driver, set to 1A
Old "build your own lightsaber" soundcard: no swing, but also no annoying flashing on and off.
1" Special White blade (The old ones from when Tim had all the colors) with polyfilm inside.

Pics:
http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3611.png
http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3615.png
http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3612.pnghttp://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3613.png
http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3616.jpg
http://i169.photobucket.com/albums/u228/Luke_SkyMarcher/New%20Sith%20Saber%20-%20Construction/CIMG3618.png

Bertuzzi
01-30-2011, 04:45 PM
That's very cool, and really sithy ;) I hope you will still have enough time to realize your projects in the future.

iamdrake
01-30-2011, 04:51 PM
Very sharp work!!! Great work on the claws!!

Darth Midian
01-30-2011, 05:36 PM
Luke that's a great job. The claws look great, the pc & grooves look great. I feel the pommel doesn't really fit the rest of the design. Overall this is a great looking saber. I also think its awesome you built your own driver board, was that difficult?

dgdve
01-31-2011, 06:33 AM
I could FEEEEL this build comming lol... very strong sith roots in that one.. took awhile but has been well worth it.. Bravo!!

Knighthammer
01-31-2011, 11:26 AM
Looks great. I'm a big fan of the claw design on it...it has me wanting to make claws - darn you man!

Jay-gon Jinn
02-01-2011, 01:49 PM
I got a chance to see this saber in person over the weekend here, and it is a very sharp looking saber in person and is very well done!

dgdve
02-02-2011, 08:17 AM
I got a chance to see this saber in person over the weekend here, and it is a very sharp looking saber in person and is very well done!

ehhh You Lucky....... man I gotta say again good job

Luke-SkyMarcher
02-02-2011, 08:36 AM
Luke that's a great job. The claws look great, the pc & grooves look great. I feel the pommel doesn't really fit the rest of the design. Overall this is a great looking saber. I also think its awesome you built your own driver board, was that difficult?

Darth Midian - what do you think would look better as a pommel on a design like this? I'm always looking to improve my design skills, if possible.


I got a chance to see this saber in person over the weekend here, and it is a very sharp looking saber in person and is very well done!

Thanks Jay! That does mean a lot coming from you. Btw your Mara Jade saber was pretty cool too - even though I didn't realize at the time that it was a petit crouton saber! Oh, yeah, and the reason the blade looked so dim was partially the batteries fault, but also partially because I hadn't added the polyfilm yet (It made a big difference when I did!)

Thanks everyone for the comments and encouragement. We'll see about whether I can find enough time for another one sometime soon. But some things, like DiffEQ, just eat up a lot of time.

Jedi_Knight_Zekk
02-02-2011, 08:40 AM
Oh... My... Jedi... That has to be the best Sith saber I've seen in a while. Great Job!

mps
02-03-2011, 04:21 PM
I think you changed my mind on "saber claws". You really made them work. Well done!