Elite Hero Personal Saber with Crystal Chassis

[Picky]

Due to the new powder coating colors avalaible, I'm planning to build a fully chromed saber: the parts will be
1-Blade Holder style 3
2-Choke style 2
3-MHS ribbed section
4-4" double female extension
5-Pommel style 3 v2
6-Insert style 10
7-Guarded style latching switch in the pommel
8-Chromed 1.5" Sink Tube
The powder coatings will be, in order:
1-Copper Vein (in the grooves)
2-Chrome Black
3-Chrome Black (in the grooves)
4-Jollypop Copper Orange
5-Xtreme Chrome
My idea is to build also a chassis, attached to the choke threading (as Madcow did with his MHS 3), so I will be able to unscrew the whole body of the saber to see the crystal and change the batteries. But here I need a little help: I will use some zinc rings for the chassis (I don't know the word in english, it is like the pommel insert style 2), do you think that a 6-32 socket head screw is ok to fix the chassis to the choke?
The little LED for the crystal will be fixed to a zinc ring with a lot of hot glue and all the wires will pass through an additional hole I will drill in the zinc rings.
The Pommel Insert will be not attached to the Pommel, but to the chassis (as LDM has done in some saber), so the switch wire will not twist.

Here the images of the project:

http://img179.imageshack.us/f/53938803.jpg/
http://img36.imageshack.us/f/73113390.jpg/
http://img401.imageshack.us/f/crystalh.jpg/

Thank you all!

[Rafalema]

Like that, your design won't work. Ribbed sections have smaller ID than main bodies, basic extensions etc.

[Picky]

Yes, I know: the zinc rings will have the right diameter for the I.D. of the ribbed extension.

[Crystal Chambers]

You mean to say discs.

I have a similar project near completion and looking at the inner diagram the inside diameter of the ribbed section is smaller then the body so your discs will be too small for the main body. I do see that the grip section will center it in the hilt and should provide enough support. I went through so many headaches considering all the options so I hope you didn't overlook anything. It is easy to.

Not bad really. Much more simple the what I have planned. Looks to me like it'll work.

I do suggest waiting if you can for the MHS sleeve material to be back in stock. The chrome sinktube is plated brass and the brass shows on the cut edges as well as inside. Also the sleeve material is nice thick.

[Picky]

You mean to say discs
Yes, I mean this: http://www.google.it/imgres?imgurl=http://www.aposiopesi.it/wp-content/uploads/images/rondella.jpg&imgrefurl=http://www.aposiopesi.it/category/societa&usg=__x2Gn3ddhGZfqG95EzsP1cEIpjuo=&h=232&w=308&sz=51&hl=it&start=0&zoom=1&tbnid=dTVFKOoU6gIxCM:&tbnh=167&tbnw=227&prev=/images%3Fq%3Drondella%2Bmetallo%26hl%3Dit%26biw%3D 1276%26bih%3D820%26gbv%3D2%26tbs%3Disch:1&itbs=1&iact=hc&vpx=349&vpy=283&dur=2062&hovh=185&hovw=246&tx=131&ty=68&ei=HYbJTPr3GdCRjAfAubDNDw&oei=HYbJTPr3GdCRjAfAubDNDw&esq=1&page=1&ndsp=20&ved=1t:429,r:6,s:0

My idea is to fix the whole chassis to the choke with a screw, so the diameter of the chassis itself does not influence its stability into the hilt. The only problem is an aesthetical one: the hole for the screw should not be totally trasversal to the choke, if so, you would be able to see the hole (looking the saber from the top). That hole should be a "depression" of the surface, I'm sorry I'm not able to explain well the idea: I'm not a champion in english! In some time I will draw a picture: wait for it!

EDIT: The picture: I hope this helps! The correct hole is the blue one, the red one is the too long one.
http://img233.imageshack.us/img233/4655/drillhole.jpg

[Crystal Chambers]

So you need a stop on your drill bit so that you only drill so deep. Or a short drill bit. I'm not sure If I used the correct term but I think you know what I mean.

And then threaded rods, tubes, and washers?

I think 6-32 will be good. Although I think you can use threaded rods the whole length. I'm using 4-40 but mine are only 5" long

[Picky]

There are bad news: I tried to drill the washers but they are too solid: my drill failed to drill them :( ! I will search for some plastic disk, but is not easy to find them... I neither know where to search them!

[equinox13]

can you get aluminium washers? what about old hard drives? you can use the disk that holds the platters in place.

[Lord Dottore Matto]

Very cool project. Aluminum washers will work much better for you.

[Picky]

Thank you all for the suggestions! I found a solution in using a stronger drill bit. Now the work needs a lot of strenght, but I can drill the washers!



EDIT: This is very strange: also the stronger drill bit sometimes works and sometimes doesn't work: I fix it very well into the drill tip, but when I move down the lever of my drill press to go against the washer, the bit goes up into the drill tip's hole and does not drill the washer. Well, this is really an unfortunate period for me, but I don't understand why the drill makes so...