Cardcollector's "Rak Kazakh" Build thread

[cardcollector]

Hey guys,

I decided to take a few pics on a build I am working on and make a build thread. I don't know if any of you guys will benefit from it, but I thought some might enjoy looking at the way "I" build my sabers...

So, here are the parts for the saber, I must mention, the TCSS driver board is not going to be used. It was to expensive for the client.
https://lh4.googleusercontent.com/-VeOUOLg46Zg/Tf17Fa4ZmKI/AAAAAAAAAHo/i1fzgcim9hQ/Rak%252520Kazakh03.jpg

So, I started with the activation box, since this will be the majority of the work on the hilt.
https://lh6.googleusercontent.com/-fANjsNtrBLQ/Tf17HRRHMXI/AAAAAAAAAH0/m5FSpZsQxSY/Rak%252520Kazakh06.jpg

I measured and aligned all the holes with a caliper, and drilled everything out like so...
https://lh6.googleusercontent.com/-DOxhzEJl_ts/Tf17JifC5CI/AAAAAAAAAIE/IaDdHSzs2Eg/Rak%252520Kazakh10.jpg

The box will be mounted on a 3" DF extension, So I had to drill into the threads. I also had to shave some threads off of the Male end of the Ribbed extension. A dremel cutting disk was used to do so.
https://lh5.googleusercontent.com/-ivmIpXsMJes/Tf17H9wk0YI/AAAAAAAAAH4/mwdbPWEvkfU/Rak%252520Kazakh07.jpg
That was way to stressful for me to be doing that again anytime soon...

Viola!
https://lh5.googleusercontent.com/-0L14X2hR2gg/Tf17KN7X3RI/AAAAAAAAAII/95TZyB10IqE/Rak%252520Kazakh02.jpg

I will post work on the overlay tomorrow.

[Loachri MacTalabh]

Just speculation, but the reason you shaved some of the threads off the ribbed extension is accept the screw to the box. As you screw the two together, the recess will allow the pieces to fit perfectly. Smart idea, I like it.

[bk_renesis]

Hey CC just wondering why you drilled out holes for the box rather than making a cutout?

[Skottsaber]

Most likely because he doesn't have a mill.

[bk_renesis]

I performed a "cutout" on my first MHS that I updated with a control box using a dremel and files, worked beautifully. But on my contest saber I got Tim to mill it out. Either way works great. I just see the holes as being restrictive, I could be wrong.

[cardcollector]

Hey CC just wondering why you drilled out holes for the box rather than making a cutout?

Because drilling is quicker than cutting and filing. This one is on a rather tight schedule, so holes were the easiest route with this one.

And no skott, I have no mill. :(

Oh, and loarchi, that is exactly correct.

[cardcollector]

Double Post, but I think y'all wil forgive me.

Overlay time...
I decided to use MHS sleeve material for this overlay instead of sinktube as it will be painted... and the material is nice and thick.

First off, The template is glued to the MHS piece. Rubber cement is a favorite of mine to use as it keeps the paper on and peels off the metal easily.
ONe side...
https://lh4.googleusercontent.com/-HRRCuD5jyzM/Tf17LCF6TnI/AAAAAAAAAIQ/BI3fpB0Sjkg/Rak%252520Kazakh17.jpg
and the other...
https://lh6.googleusercontent.com/-QwQRyf7GNik/Tf17LjOqQtI/AAAAAAAAAIU/iUzZHPt2ys0/Rak%252520Kazakh18.jpg

Using a dremel with a "Thin cut" disk... We get this;
https://lh5.googleusercontent.com/-kip4BucTJBk/Tf17MM0rdgI/AAAAAAAAAIY/aNfJ1D2CO9k/Rak%252520Kazakh19.jpg
https://lh6.googleusercontent.com/-IGwSfilTSoU/Tf17MgYOD7I/AAAAAAAAAIc/4U3hW8a8e9I/Rak%252520Kazakh20.jpg

And the other side...
https://lh5.googleusercontent.com/-jrU9TawcEwI/Tf17M2PEyWI/AAAAAAAAAIg/CYEp3kczxQM/Rak%252520Kazakh21.jpg

Now to go to work with some files...
https://lh3.googleusercontent.com/-sUdX3k0tDuM/Tf17NyyOVsI/AAAAAAAAAIo/0-5GnLmq7mo/Rak%252520Kazakh23.jpg

https://lh6.googleusercontent.com/-gvzsgn5WlCM/Tf17OFxs0dI/AAAAAAAAAIs/gKx8SVQvu8E/Rak%252520Kazakh24.jpg
Much better, still not perfect, but headway is being made... I will come back to that side with some sandpaper later...

Now, back to the angled side, I traced the activation box around the overlay piece, cut it out, and filed it the same way...
https://lh6.googleusercontent.com/-AOXrf24jYeA/Tf17PigaytI/AAAAAAAAAIw/TZmeLcRABWs/Rak%252520Kazakh12.jpg

Those hard lines bug me... let's take some 400 wet sandpaper to those lines...
https://lh6.googleusercontent.com/-Vkk35wfQK6U/Tf17P46BusI/AAAAAAAAAI0/nqReSA7uFEE/Rak%252520Kazakh13.jpg
Much better.
You can see a little ding in the lower part of the piece.. couldn't sand it out... it is there to stay.
The piece is also setup to polish. The paint it a trans blue, so The base needs to be somewhat chrome to make the paint job look right...

Finally, It is all polished up and ready to paint. (which I am doing this evening)
https://lh6.googleusercontent.com/-3tTcrzOTAX8/Tf17Rlr2_UI/AAAAAAAAAJE/SRSpiw6p_aE/Rak%252520Kazakh11.jpg
https://lh5.googleusercontent.com/-ynCKgNMq-qQ/Tf17Rc_eK3I/AAAAAAAAAJA/pW1jP3b2nx0/Rak%252520Kazakh16.jpg

More to come soon...

[Xanatos1986]

I think this will look really nice I cant wait to see more.

[Tarrell]

Comming along nicely, Cant wait to see it finished.
Shame about the ding, but if you ever decided to weather it, im shure the ding will fit right in, ;)

[Knighthammer]

So I've got to ask CC, is the vice just loose on the drill press? To me it looked like it might not be attached since you use it for you shroud work as well.
Just wondering cause I'm still having a hard time mastering the drill press / vice thing. (getting everything 100% lined up correctly).

[cardcollector]

Comming along nicely, Cant wait to see it finished.
Shame about the ding, but if you ever decided to weather it, im shure the ding will fit right in, ;)

Yeah, it is too bad, I just got finished painting tonight and it isn't to noticeable. Just a little dark spot. I am happy with it, personally, I think it adds character, but that's just me...


So I've got to ask CC, is the vice just loose on the drill press? To me it looked like it might not be attached since you use it for you shroud work as well.
Just wondering cause I'm still having a hard time mastering the drill press / vice thing. (getting everything 100% lined up correctly).

That is correct, I do not attach my vise to my stand. I align everything with a piece of track shelving. The way I get all the holes right on top of the rounded piece is to use the light on the hilt. It makes a line exactly at the highest portion of the hilt. All I have to do is rotate the pieces so it is on that line.

[bk_renesis]

Looking good, will follow this one to see the end product.

[Loachri MacTalabh]

Filing. The smallest file I have is about 8"L X 1"W. I can get in most spots with it, but really tight areas are a no go. You seem to have found what works. My question is; Where can I get some tiny files like what you use?

[hebert466]

i will be following this build...:mrgreen:

[Knighthammer]

My question is; Where can I get some tiny files like what you use?
Lots of places...Sears, pretty sure Home Depot / Lowes, I'm sure Ace or Frieght Harbor might have them too, I got mine from Snap On, I'm a sucker for their tools.

[Loachri MacTalabh]

Thanks Nighthammer, I didn't even think of Snap-on or Mac.

[(null).exe]

Snap On, I'm a sucker for their tools.

If I won the lottery, the first thing I would do is buy at least 1 of everything, and 2 of most.

/Snap-on Fanboy

[Jedi-Loreen]

Look for jeweler's files. They are very small and fine.

[cardcollector]

Filing. The smallest file I have is about 8"L X 1"W. I can get in most spots with it, but really tight areas are a no go. You seem to have found what works. My question is; Where can I get some tiny files like what you use?

Sorry about the delay in response... Life came up. :(

Anyway, I have a Kobalt File/Screwdriver set I purchased at lowes. Nothing special of expensive.. They just get the job done. J-lo's recommendation to look for Jewler's files is a great one. I have found files are the secret to great overlays... and patience... and time...

As far as the build goes, I should finish painting and begin installing the guts tonight... The saber will be finished by the end of the week, so keep your eyes peeled for updates! :cool:

[jin starkiller]

you also might want to check places like Harbor freight and Northern tool they usually carry jeweler files they come 4 or 5 to a set

[Loachri MacTalabh]

Sorry about the delay in response... Life came up. :(

No Worries!;) I know how life works. Others stepped up and gave me some good options. Thanks all!

[Jedi-Loreen]

I don't remember where I got my files, maybe Lowe's? They are called needle files and my set has (had) 12. Several different flat ones, half rounds, round, 2 different triangular ones, a square one.

My favorite flat I was using at the last long term temp job I had. Apparently one of my nice co-workers permanently "borrowed" it and I never found it. :mad:

[(null).exe]

Harbor Freight (for all their pros and cons) has a pretty nice set of jeweler's files (called "Jeweler's Files" on the package, oddly enough) that are less than $20 for the set.

[Azmaria Dei]

i have like 3 various sets that i've picked up here in Japan. i don't recommend flying out here just for that though - grab some ramen at Ichi Ran in Machida while you're here. ^_^

[cardcollector]

Alright, update time. Good news is the saber was finished today like scheduled and was presented with large amounts of awesomeness. I will go into that more in the Gallery thread though... you guys want to see build pics... :razz:

So, The hilt was painted and baked, time to install some electronics. For some unknown reason, my MR yoda board just flat out failed... which was probably the worst thing that could have happened, I talked to the customer, and they said go ahead and use a cheaper economy board... so I did. :(
Anyway, such is the way of saber building, I moved on with that, and made a nylon chassis for the board and 3.6V lI-ion cell...
https://lh6.googleusercontent.com/-NdBHDSQkoFE/TgVcMqi2ZbI/AAAAAAAAAMg/1rWCHRC4lJs/Rak%252520Kazakh%252520wiring%252520%2525285%25252 9.jpg

Next, I cleaned up the board, replaced the wires, etc... and mounted the board and cell like so.
https://lh3.googleusercontent.com/-mSDM0eML2vE/TgVcNIzhNAI/AAAAAAAAAMk/ZQctnYFJT1w/Rak%252520Kazakh%252520wiring%252520%2525286%25252 9.jpg

And heatshrunk to the chassis... this board ain't goin' nowhere *ribbs J-lo*:p
https://lh4.googleusercontent.com/-xGBWsLalKSI/TgVcNhNk5wI/AAAAAAAAAMo/118aVMCdOjw/Rak%252520Kazakh%252520wiring%252520%2525287%25252 9.jpg

Chassis with board installed in the ribbed section and choke. A perfect fit!
https://lh6.googleusercontent.com/-cuOZS-4Lbmk/TgVcOJ7YVAI/AAAAAAAAAMs/RZAU-uqbA4s/Rak%252520Kazakh%252520wiring%252520%2525288%25252 9.jpg

https://lh5.googleusercontent.com/-jJ06OM_53JE/TgVcOofZTnI/AAAAAAAAAMw/JsKWaTMxE6g/Rak%252520Kazakh%252520wiring%252520%2525289%25252 9.jpg

That's alotta wires...
So next i wire up the switch and recharge port, this was tricky, but Everything eventually found their place.
https://lh3.googleusercontent.com/-73m9fdizukY/TgVcPSrEf7I/AAAAAAAAAM4/EFeX37sM914/Rak%252520Kazakh%252520wiring%252520%25252811%2525 29.jpg

So now all we have left is the crystal pommel. Here's what we got.
https://lh6.googleusercontent.com/-g9fCA8bh4T8/TgVcKrQi-hI/AAAAAAAAAMQ/4hV_i-pC0U0/Rak%252520Kazakh%252520wiring%252520%2525281%25252 9.jpg

The crystal is sanded down so it will fit in the pommel section with the speaker sitting flush over it. The LED wires will hold the crystal in place...
https://lh3.googleusercontent.com/-SFos1CvwhVA/TgVcLnQTvRI/AAAAAAAAAMY/TiTtqLC-ZOc/Rak%252520Kazakh%252520wiring%252520%2525283%25252 9.jpg

https://lh4.googleusercontent.com/-PGAtNCNz-Uw/TgVcPsjAD5I/AAAAAAAAAM8/3NlL8cNVBxk/Rak%252520Kazakh%252520wiring%252520%25252812%2525 29.jpg

I sanded a section a PVC to fit in the pommel for a speaker mount. Works pretty well methinks...
https://lh5.googleusercontent.com/-prdy7hcG5sU/TgVcQDFr8xI/AAAAAAAAANA/F07Xj08pRMI/Rak%252520Kazakh%252520wiring%252520%25252813%2525 29.jpg

and now... the big moment... The first turn on!

https://lh6.googleusercontent.com/-TtDkCwHAweQ/TgVi5gByB8I/AAAAAAAAAPg/uskVDdC8C-s/Rak%252520Kazakh01%252520%2525282%252529.jpg

YAY!!! It works! :mrgreen:
Expect a Gallery thread in a day or so... Depends on howm uch Time I have to make the vid.

Questions? Comments?

[Loachri MacTalabh]

WOW! That is One Good Looking Saber. Your best to date. Does the box keep the shroud in place?

[cardcollector]

WOW! That is One Good Looking Saber. Your best to date. Does the box keep the shroud in place?

Thanks dude, This is definitely one of my favorites...
The shroud is epoxied to the extension, and just aligned with the box.

[bk_renesis]

Love the flat black on this saber, looks great. Looks like an aux switch is wired to the box for activation and av switch is a dud? Future upgrades to PC maybe?

And look who ended up with a cutout under the box!

Awaiting gallery thread and video. Very nice.

[stegasp]

Wow. The flat black with the blue accents is just too gorgeous. This really is a great build, congrats!

[Boj-Vaati Mau]

That is a sweet lokking saber, mate! Good on ya! I'd have added some of the blue near the emitter, maybe ringed the end, but that's just me. I really like the shroud too. Pray tell, where'd you get the nylon chasis parts?

[Yoshi-Taka]

The blue piece on the choke/extension really pops out. I like it. I'd love to see a video.

Was it explained earlier what that piece is? If so, I'll go reread the thread.

[cardcollector]

Love the flat black on this saber, looks great. Looks like an aux switch is wired to the box for activation and av switch is a dud? Future upgrades to PC maybe?

And look who ended up with a cutout under the box!

Awaiting gallery thread and video. Very nice.

Heheh, yeah, I wound up just cutting the darn thing out cause it was easier... doesn't look very nice though. I didn't have time to clean it up like I wanted...


That is a sweet lokking saber, mate! Good on ya! I'd have added some of the blue near the emitter, maybe ringed the end, but that's just me. I really like the shroud too. Pray tell, where'd you get the nylon chasis parts?

I got all the Chassis parts at ACE. I took the extension, and just put washers in the hilt till I found one that fir perfectly. Then I got some nylon spacers... 6-32 nuts... 6-32 threaded rod... and the chassis was born. :) Really great stuff to work with, nonconductive, easy to shape... I like it a lot. :)


The blue piece on the choke/extension really pops out. I like it. I'd love to see a video.

Was it explained earlier what that piece is? If so, I'll go reread the thread.

No ,I didn't explain that, it is just a piece of mHS sleeve material I cut with a pipe cutter and slid on the female end of the ribbed extension. Nothing fancy, just adds a little balance to the lower portion methinks...

BTW guys; Glam thread is up.
http://forums.thecustomsabershop.com/showthread.php?13118-Cardcollector-proudly-presents...-quot-Rak-Kazakh-quot-A-MHS-Custom-Saber

[Ronan]

Look for jeweler's files. They are very small and fine.

God no... My jeweler set was like $250.

Get cheap metal files, the small one's, that you find in every hardware store. Canadian Tire and Home Depot sells them for $15.

[KuroChou]

A set of *true* jewelers files might run you that much, but in a lot of hardware stores regular old miniature files might be labeled as jewelers. I got mine at Harbor Freight for ~$5.