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View Full Version : Jay-gon Jinn's Brass Saber 25 (Petit Crouton, Li-Ion, 1 1/4" sink tube ,RGB purple)



Jay-gon Jinn
07-30-2011, 11:20 PM
I had a friend of mine in the Rebel Legion ask me about building a saber for his fiancee that wanted to join the group with a custom Jedi costume and this will cover the build. I'll be using these parts to build it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/43227afa.jpg
What we have there are:
-8" double threaded female connector
-Blade holder style 13 (New design)
-MPS pommel style 4
-box 2
-MPSI style 1
-white 1" thin-walled blade tip (the blade will be a trans-white as this helps with color mixing)

The basic design for this one has turned out to be no different than most of my brass sleeved (or chromed for that matter) but with a little twist added in. You'll see what I mean later! ;)

I set up the 8" MHS extension in the vise on my drill press after marking it off for the work I was going to do:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/3bec0b06.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/6f36ae7a.jpg
As you can see, I drilled some holes in the 8" extension....then I took the Dremel to it with a reinforced cutting disc:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/d7edba5d.jpg

I flipped it over in the vice and set it up to drill two more holes:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/4fb520ae.jpg

Then "slotted" those two holes as well:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/7da7a248.jpg

Moving to the rear half of the 8" extension, I drilled some more holes:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/71956811.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/e17984df.jpg
Then I again used the dremel to remove the unwanted section of hilt:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/498e2c71.jpg
Next I spent several hours over the course of a few days filing and sanding on the extension. Prior to working on it all, I had also wet-sanded the extension with 800 and then 1000 grit wet-dry sandpaper and polished it to a chrome-like finish.

After that was done, I moved on to locating the switch box:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/a55419a9.jpg
Then drilled the holes for the switches, recharge port, and mounting screws. I also tapped the mounting screw holes for the required 6-32 threads:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/574ea26e.jpg

Now, the thing to keep in mind about the MHS parts is that you can sleeve them using the TCSS sleeve material or a chrome plated or polished brass sinktube, but they can also be used as the sleeve itself because the inside diameter just happens to accommodate a 1 1/4" sink tube perfectly!

So, I sanded down a 20-gauge chrome plated 1 1/4" threaded tube to the brass, and then cut it to the proper length to fit inside the 8" extension. I de-burred it and test fit:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/e614fd10.jpg

A closer look at the rear grip:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/1223a182.jpg

The front grip:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/e2f9bdc8.jpg

And the saber test assembled:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/f09faf79.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/4c8ebde8.jpg

As it turned out, I decided I didn't like that blade holder for this...it just looked to "chunky" on it, so I ordered a replacement style 8 instead:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/e35dacf3.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/967b1d83.jpg

Jay-gon Jinn
07-30-2011, 11:23 PM
The owner liked the saber with the style 8 blade holder better, and that was what was chosen to stay on the saber. I'll have to find another use for the style13.

I got to looking at it after installing that blade holder and thought the neck of the emitter looked pretty close to the same size as the brass tube, so i got out my calipers, and sure enough, it was 1.2", really close to the 1.25" of the brass tube. I got to thinking how cool it would look if the neck of the emitter was made in brass it would look like the saber was built on a single brass tube, and that got me thinking about asking Tim about doing modular Blade holders, where you could unscrew the emitter face, and replace or sleeve the emitter neck. That would likely never happen so I did the next best thing....I wrapped it in a piece of brass sinktubing that I cut, filed and sanded to fit. After getting it fit properly, I used some two-part epoxy and a hose clamp to hold it in place while I went to work and then overnight:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/3346b252.jpg
I just snugged up the clamp and had taped the brass to protect it.

The next day, I removed the hose clamp:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/2bc4a31a.jpg
Success! I think the saber actually does look like it has a single brass tube running up the center! I had also added scoring marks to the inner brass tube in the hilt to make it look more like a grip, but forgot to add them to the brass piece I added to the blade holder. Oh, well, maybe next time, since I'd like to do this in chrome as well.

I also wanted to have more gold/brass color on this one, so I placed another order from the store at TCSS and got a gold plated momentary switch and a brass CT button. I received the parts a few days later, and tried them out:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/49b7163c.jpg

I also wet sanded and then polished the blade holder to remove the excess epoxy and give the brass a good shine:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/f592975a.jpg

The switch box with the switches and recharge port installed:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/0484924b.jpg

Here's the rear grip section:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/c54da58e.jpg

The underside of the rear section:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/c1ed86ec.jpg

This needs some more work here, I think:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/0ffc77c5.jpg
I am probably going to cut another slot here, just in front of the CT wheel, and right about to the opposite spot under the switch box where the first slot stops, just to try and maintain some symmetry.

Since the owner is not in a hurry for this one, it will take a bit more time to get it complete, but next up will be cutting the rear slot, and then possibly clear coating the hilt pieces to maintain the shine, or not, depending on if the owner wants it done.

After that, the plan is to begin the wiring. The saber will be running a PC powered by removable Trustfire Li-Ion 14500's (this is a costume accessory, so it needs to be able to have the batteries changed while at a 4 hour + event) and will have a violet main blade led that can be swapped out for a hot pink one.

Boj-Vaati Mau
07-31-2011, 05:59 AM
Great looking saber, Jay! I, too, think it'll look better with the slot near the CoverTec button.

Yoshi-Taka
07-31-2011, 07:12 AM
Looks pretty awesome. I agree, it looks a lot better with the second blade holder.

Jedi_Knight_Zekk
07-31-2011, 07:55 AM
Saber looks awesome as usual Jay! And I agree with everyone else. It looks a heck of a lot better with the second blade holder.

KuroChou
07-31-2011, 09:51 AM
Loving every inch. For some reason something about this one makes it feel much more canon than most of your other sabers.

kcdill
07-31-2011, 10:04 AM
I love the look of the brass tube and the finish is exceptional.

Bertuzzi
07-31-2011, 12:50 PM
In my opinion this design is one of the best you already made. It also should be quite handy.

captain_mills
07-31-2011, 10:20 PM
Wow... just, wow...

Ditto all the comments already made. I love the design and the brass is great! Very classic look to this one.

Crystal Chambers
08-01-2011, 05:42 AM
Nice! Although I think it looks a bit bare without an overlay..lol JK. With the large sections cut out of the body how sturdy of a build is it? I'm guessing the underlay will add some strength if it's full length. I like what you did with the emitter although I'm curious to see how the seam worked out.

Elodin
08-01-2011, 07:05 AM
Looking good! I like the use of MHS on the outside. Does it feel slimmer over all in the hand?

Jay-gon Jinn
08-01-2011, 08:46 PM
Nice! Although I think it looks a bit bare without an overlay..lol JK. With the large sections cut out of the body how sturdy of a build is it? I'm guessing the underlay will add some strength if it's full length. I like what you did with the emitter although I'm curious to see how the seam worked out.

The seam is right here:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/d3daba37.jpg
It's not too noticeable, but it's there.


Looking good! I like the use of MHS on the outside. Does it feel slimmer over all in the hand?
Yes, it does feel a bit slimmer in the hand than it would if I had used a sleeve over it.

Crystal Chambers
08-02-2011, 05:45 PM
Hey not bad. The metallic reflection hides the line a bit.

Jay-gon Jinn
08-02-2011, 10:23 PM
I did some more work to this saber yesterday. I assembled one of the new TCSS led modules with the led. If you haven't used one yet, here's how they go together:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/2690d4ca.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/1fefd299.jpg
This is how it comes from TCSS...assembled.

The heatsink unscrews:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/8c2b6bf1.jpg

I mounted the led using a heat transfer adhesive pad and added a QD plug:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/0f43ff73.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/2d9bb8e2.jpg
The wires fit perfectly into the channels in the side of the heatsink.

I added the lens and screwed the heatsink into the housing:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/7c893ba6.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/1a3ade4b.jpg

Finished:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/99f78f77.jpg
These will make swapping out led's for a different color blade much easier because now you don't have to worry about having the lens fit the holder, aligning the holder and lens correctly on the led, etc. This saber will be getting used for costuming purposes, and it's the owner's first lightsaber, so the simpler it is, the better.

Back to the work on the hilt, I also managed to get that other slot finished. I started again by drilling two holes:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/a13a9443.jpg
Then "slotted" them using the cutting disc on my Dremel. Then after a little "quality time" with a file, and I had a fairly straight slot:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/e412c434.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/e4f8b150.jpg

I then sanded and polished the edges of the slot and re-assembled the hilt to check it out:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/5180c235.jpg
Not bad....it's bit smaller than the forward slot, but that's okay:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/3c60b1f0.jpg

With the rest of the hilt:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/449c5321.jpg

With that done, all of the machine type work on the parts is pretty much finished, so I took it apart again to get ready for some final sanding and polishing before final assembly:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/b6879f3d.jpg
I'm thinking I may want to try and clear coat these before assembly, just so the shine can be protected....the polished aluminum MHS parts are very easily scratched right now, and I think a coat of baked -on clear enamel might help with that.

captain_mills
08-02-2011, 10:42 PM
Jay-gon,

Your explanation on how the new LED/Heatsink go together is exactly what I've been looking for! You are amazing, as usual, but you just scored extra-credit with me... I dunno if anyone else appreciate's this, but at least you made a difference for one!

Thanks!

hebert466
08-03-2011, 12:16 AM
you have just givin me alot of ideas for my next saber...thanks! oh, and by the way...it looks GREAT!!!:mrgreen:

Noyl Wendor
08-04-2011, 08:13 PM
Wow, nice work. I think thats along the lines I was going. I am posting a couple of updated pics of my saber in my build thread. Similar to yours Jay, only not nearly as nice looking. Again great work. :)

Jay-gon Jinn
09-16-2011, 12:08 PM
Update on this saber's constructionn.

I made the soundboard cradle for this one a few weeks ago, and here's how it turned out:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/514cd38e.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/91b24d6b.jpg

This will need to b secured to the hilt somehow, so I drilled and tapped the chassis disc for 6-32 threads. This will line up with the forward mounting screw for the switch box:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/2183c7b2.jpg

The finished cradle/mount:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/355aa0d9.jpg

The soundboard will mount to it like this:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/dc061959.jpg

Then today, I clear coated and baked the MHS parts:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/a5780711.jpg

While they were baking, I worked on the wiring and added the wires to the board:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/4e699643.jpg

With all of the wires attached to the board, I began to assemble the saber by running the wires for the speaker and battery pack through the hilt sleeve:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/e9774df2.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/f8240b84.jpg
I can do this while the rest of the parts are baking in the over, because I already clear coated the inner sleeve.

With the wires all threaded through the hilt and the chassis disc, I soldered the speaker wires to the soundboard:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/da4d91ed.jpg

I slid it all into the hilt and lined up the mounting holes:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/131d5682.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/8362bdaf.jpg
The mounting screw fits perfectly in the chassis disc:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/12fe3b6e.jpg

After I finished this, I decided to go and check on the parts, and found out that you really shouldn't bake parts that have been adhered together with epoxy:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/0336c2e7.jpg
I'll have to re-epoxy this and simply clear coat the emitter the old fashioned way. ;)

Mandalorian
09-16-2011, 02:12 PM
Awesome! Very clean setup there, and you just helped me solve some wiring issues that I've been having with that board mounting idea. So thanks. That baked epoxy incident is also very helpful.

It's looking great Jay. I'm sure the customer will be one happy person, especially since it's their first saber. Great intro for them into the world of sabers.

Jay-gon Jinn
09-16-2011, 06:20 PM
Okay, after three hours in the oven this afternoon, the parts were dry, so I began assembly:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/5272dde2.jpg

I wired up the switches and the recharge port:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/210429a0.jpg

Then assembled the switch box to the hilt, making sure to aign the soundboard mount with the front mounting hole so the screw would thread into it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/521708e6.jpg

Then got ready to install some batteries:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/1dea4ce1.jpg
Got them in, and found that I had glued the speaker to low on the battery holder for the battery pack to fit into the saber properly so had to spend a half an hour re-doing the battery pack and speaker assembly.

I did that and also re-epoxied the brass piece on the emitter, and also loaded up the SD card with Madcow's "Bespin II" font then assembled the emitter and led assembly to the saber:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/459c37a3.jpg
I had to make a change to the led's resistor to tweak the color, and then reassembled it and tested:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/c31c9d6c.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/41a70e6c.jpg

Full blade shot:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/0ee9d582.jpg
I think that'll do!

I'll still have some clean-up n the blade holder to do, and I have yet to actually make the blade for this one as that is the one I have been using in CS-X lately, and then I can get some final beauty shots taken hopefully on monday, along with a video.

Mandalorian
09-16-2011, 07:02 PM
Wow, that looks great. Can't wait to see it finished without the neck clamp, as well as the video.

This reminds me a lot of Mace Windu's saber.

cannibal869
09-17-2011, 10:11 AM
dang man that is B@d@$$!! very nice work there!

Jay-gon Jinn
09-23-2011, 08:33 AM
Finished it...full spread of pictures in the gallery soon, but here's the final piece:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Custom%20saber%20for%20Zod/02eed817.jpg

Mandalorian
09-23-2011, 10:38 AM
Great! Can't wait for the video.