Boshwan527's Starkiller TFU1 Build - First Saber

[boshwan527]

Hello everyone

This is my first thread and my first saber build! I hope you like it so far.

First I must say I have to give credit to this guy for a lot of inspiration:
http://3.bp.blogspot.com/_LBoiJX-K6F8/S_pggY31GcI/AAAAAAAAA9g/77lfal3M0zI/s1600/STARKILLER+Galen+Marek+I.lightsaber.jpg
RO-LIGHTSABERS: RO-LIGHTSABERS (http://ro-lightsaber.blogspot.com/p/lightsabers_11.html)

I've always been more concerned with making things look how I would idealized them in my head as opposed to being super screen accurate, so this won't be exactly like game version.

Anyways, Here are some preliminary models i made:

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/SK1.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/SK2.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/SK3.jpg

And here is some of the machining process. The emitter shroud I actually had cut on a wire EDM machine and it turned out really well:

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00204.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00205.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00206.jpg

[boshwan527]

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00218.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00219.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00223.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00226.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00225.jpg

Took some scothbrite to the outer pieces to get that weird haze off and it looks way better. I also started on the long switch. It's almost done but I didn't have tome to cut the grooves for those thin inserts:
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00227.jpg

Anyways, that's where I'm at so far. Let me know if you have any comments or questions. I'm not going to do full sound and blade or anything. I'll be using a rebel star to light up the crystal chamber, which I plan to build Slothfurnace style.

Thanks for reading!
Evan

[bk_renesis]

Wow very nice work, will keep an eye on this one.

[Xanatos1986]

I'm Intresred in the control box and card/cover please explain. Nice so far.

[boshwan527]

The control box is just going to be for show. This will be a mostly static build as it's my first one. From the last picture: Those to skinny insets will go into the top part of the control box, like in my 3D model, I just have to mill the slots. I'll most likely just screw/epoxy all those pieces together in the "closed position" for show. In front of that box I'm gonna put a red illuminated DPDT switch that will activate the LED for the crystal chamber (not pictured in my 3D model).

Does that answer your question?

Thanks for the responses guys :)

[bk_renesis]

Static build???? No way man, this thing would be so easy to convert. What's the ID of the inner tube? I bet a 1.25" sinktube blade holder would fit easily and the fins on the heatsink exposed in the crystal chamber would look awesome. It would just be a shame to leave it empty. Here is a pic of a MFX Starkiller that I converted to give you an idea of what I'm on about:

http://i1014.photobucket.com/albums/af267/bk_renesis/2acac2a1.jpg

you can find the holder here (http://www.thecustomsabershop.com/125-Sink-tube-LEDBlade-holder--P269.aspx).

[boshwan527]

Haha, you make a good point. I guess I'm just nervous about wiring all of the extra stuff up. I was never too into the blade and sound stuff, but I actually watched a video of someone lighting theirs up like two days ago and it was really cool.

Here's my progress for the day:
I milled out the slots in for the accent pieces on the activation box. I drilled and tapped the saber and the activation box and attached the two with sets screws.
I also machined a new bezel for the DPDT button so it's height matched the activation box:

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00228.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00229.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00230.jpg

[bk_renesis]

This thing is just getting nicer!

[boshwan527]

Thanks! I won't have time to work on it for about a week as I'm going out of town. I'm trying to decide what to do next though. It's between the grips and the emitter ears. I think I'm gonna go with the ears first because I think it would make it look super awesome, though I think that's gonna be the hardest part to machine like I've modeled it

[bk_renesis]

If you pull it off will be the best bunny ears ever! awaiting updates...

[Xanatos1986]

like the switch it looks clean.

[ghost_a*]

looks damn good man. love the activation box. very nice.

[Mandalorian]

Very cool so far. It's a nice, clean design and it all works very well together.

Curious, what program did you use for those models?

[boshwan527]

Thanks! :)

I modeled them in SolidWorks originally but my license on my desktop at home ran out so I imported the models into Autodesk Inventor and I've been working from there now.

[boshwan527]

Ok so I did the emitter ears today. I decided to "freehand" all the angles to give it a more rugged look and it turned out ok. I'm not sure if it's because I got used to seeing it without the ears, but I'm not in love with them like I thought I'd be haha. Honest opinions...how does it look? Maybe they're too far forward?

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00232.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00233.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00234.jpg

[Ronan]

Too far forward and slightly too tall.

I'm shooting you a PM please reply.

[boshwan527]

Yeah I think I'll move them back a little. They're actually shorter than the ones on a graflex...maybe I'll take a little off the top though :) Checking my pms now

[Skottsaber]

I like them, actually. They remind me of a sort of clone wars style, where the traditional sabers were given a redo in the style of the animation.

[Mandalorian]

I agree that they're a little too far forward and looks a little too tall. I do like the design though, just needs a little TLC, that's all.

[boshwan527]

alrighty then I guess I'll move them back a little and take a bit off the top...thanks for the feedback guys :)

[boshwan527]

Minor progress today. better than nothing though :) So I moved the ears back as much as I could without the old hole showing. It seems like it did the trick though...thoughts? I don't know, I got so used to it being the other way, now it looks weird again haha I haven't made it any shorter yet. That decision is harder to reverse lol.

I also cut some grips down to size. They look pretty good proportionally. I'm planning on tapping them through the bottom then using set screws to secure them to the main grip cylinder from underneath. Then Ill round them off and everything like in my model. That'll be my next step:

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00235.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00236.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00237.jpg

thanks for looking :)

[bk_renesis]

The bunny ears will look proportional when you insert the emitter piece I believe. Looks great.

[boshwan527]

Thanks! That's what I'm hoping for. I think you're right though, I can't wait to get that part done.

The dark side grows stronger in me ever day :-P I got the "grips" attached today and all finished up. It took my like four hours >:(
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00238.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00239.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00240.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00242.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00241.jpg

[bk_renesis]

Niiiiiiiiiiice!!!!!

[Rafalema]

Great work.

What did you use to make the models?

[boshwan527]

Thanks guys! I'm really happy to have gotten this far. I started about a year ago and got the emitter shroud cut then stopped cuz I got overwhelmed with how much work I thought it would take. It's really starting to come together :) I'm not super excited about doing the crystal chamber, or the electronics for that matter. But maybe I can get some help with that later :-P I have some ideas for the chamber, but I'm just hesitant to get started without a perfect idea. Maybe I'll pass my ideas by Sloth haha what I have is mostly derivative of his awesome stuff. (I hope that's ok!)

@ Rafalema: I modeled them in SolidWorks :) The pictures I have at the beginning of the thread are in Inventor though because my SW license expired and I work at Autodesk now haha

Thanks for the interest guys, definitely helps me stay motivated

[Crystal Chambers]

I'm kinda mixed on your interpretation but I like how you're making it your own and the work looks great so far. Looking forward to seeing how it turns out.

[boshwan527]

I'm kinda mixed on your interpretation but I like how you're making it your own and the work looks great so far. Looking forward to seeing how it turns out.

What is it you like better about the other one (or dislike on mine) if you don't mind me asking? Just curious :)

[Crystal Chambers]

The ears on it look great but in this case I prefer the more graflex looking ones that are done often. The original ones seem to mimic the emitter like a graflex. The shallow angle of the emitter shroud leaves a little too much exposed both in length and depth. The lower portion of the shroud looks more comfortable but I've grown accustomed to seeing the square corners. I think the box might look better higher without the AV switch since the box can accommodate switches. All of these features look great on their own but I'm not sure if these alterations are the best choices to customizing a starkiller IMO. Just being picky. The work looks great and I might end up biting my tongue once it's done.

[boshwan527]

Thats funny about the emitter ears because thats what I've always liked the least about other starkillers. I totally feel you on the graflex feel though. It just seemed like they could never match up so I thought I'd try something different. I also see your point with the activation box being higher. That's originally how I had it in the drawings on the first page. I think that just came down to the fact I've really liked the lit AV switches and they're so long that was the only place I could put it.

And on your last point I hope that when I get the actual emitter in there that it migh look better :) I guess we'll see shortly. Thanks for the honest feedback, much appreciated.

[Crystal Chambers]

Anytime. I do the same with my own builds. Always second guessing. I'm not big on replicas so I like to put my own twist on them too which is one thing I can appreciate about this build. There's a lot of give and take in saber design when it comes to what's possible. The addition or alteration of one feature can limit or dictate the direction of another. This is a challenge that I really enjoy about designing sabers.

[boshwan527]

I had an LED question I was hoping someone could help me with. I'm not going to use a sound card to start with. I'm just going to run an LED for the emitter and an LED for the crystal chamber. From what I've read, you can run two LEDs off one buck puck, provided you have enough voltage. What I can't find is how to figure out that voltage. I ordered a red rebel star a while ago (no particular reason why), so I'll probably get another one to match. I was going to use 4 AAA for 6 volts. can anyone help (teach) me figure out if this will work? I honestly have tried to research myself to no avail so far, so I apologize if the answer is clear

[Zzan]

The first LED will need it's input voltage but will not light until the buckpuck gets it's required input voltage of at least 5v. Each additional LED will add it's forward voltage to the required voltage.

6v won't be enough to drive two LED's that only gives 1v to the second LED. You are either going to have to add more AAA's or switch to Lithium-Ions (2x14500 (AA size) = 7.4v)

So 2 Rebel Star Reds would require 5v + 2.3v = 7.3v to drive 2 of them.

The buckpuck can handle from 5v to 32v so you could theoretically drive 32v worth of LED's if you had that much voltage coming into the system.

[Crystal Chambers]

The buckpuck requires min 5V, not the LED.

Increasing voltage isn't needed, unless you want to run 2 rebels. 5mm accent LEDs are standard for a crystal chamber.

Rebel LEDs
Red 102lm @ 700mA 2.3v
Red/Orange 134lm @ 700mA 2.3v
Deep Red 580-720mW @ 700mA 2.4v

I can't see an accent LED requiring much. Wire it parallel to the rebel with a resistor on the accent and 6V should be fine. Voltage only adds when wiring in series. Parallel will add your mA. I could be wrong since electronics are not my strong suit.

[Zzan]

The buckpuck requires min 5V, not the LED.

Right that's what I meant :) The Red Rebel Star will still only use 2.3v but won't get that unless the buckpuck gets at least 5v.

Thanks for clarifying.

[boshwan527]

If I wire them in parallel wouldn't that split the current, so the rebel star wouldn't get the 700mA it needs? Or does it not actually need that much? Could I wire them in parallel if the forward voltage of the accent led is less than 1V, or is 700mA of current way too much for an accent LED? And in your experience would that be bright enough?

Thanks for the help guys, I really appreciate it

[Zzan]

If you plan to use Accent LED's from the buckpuck you will have to resistor them. 700mA will fry them.
From the store:
Red Accent LED 2v @ 20mA
Green Accent LED 2.2V @ 25mA
Yellow Accent LED 2.1V @ 30mA

None are 1V or less.

I would probably wire accents directly to the battery pack (with proper resistors) instead of going through the buckpuck.

If I were making a staff I would drive both main LED's from a single buckpuck.

I guess it really comes down to personal preference.

[boshwan527]

I would run everything off one buck puck but I guess I'm just apprehensive about making a Li-Ion battery pack. And I already bought the NIMH charger :-P

I'll try running the accent(s) off the batteries and see how that works, and if I really need to I can change everything up.

How bright are those accent LEDs? I hope they light the chamber up nicely. So much uncertainty the first time around...it's killing me haha

[Zzan]

Tim sells 14500 protected cells (http://www.thecustomsabershop.com/TrustFire-Protected-37V-900mAh-14500-Lithium-Battery-2-Pack-P342.aspx) in the store.

Just buy 2 (1 pack of 2) of those and a AA battery holder (http://www.thecustomsabershop.com/2AA-Battery-holder-P348.aspx) then use them just like you would regular AA's except charge them with a Li-Ion charger (http://www.thecustomsabershop.com/TrustFire-All-in-One-Charger-P346.aspx) (which Tim also sells) and realize they will give off 7.4v instead of 3v that 2x normal AA's would. You don't have to do any soldering to them or anything. It's not a good idea to use a recharge port with multiple cells that are individually protected, but removing them from the saber and charging them in the Li-Ion charger is perfectly ok.

[boshwan527]

oh cool. I wasn't sure if you could use those with a normal AA holder. I was planning on doing a recharge port, but if it's better without it than no-biggie. I'm not sure I'll need to recharge them all that often anyways

I'm convinced then. Two luxeons off one buck puck with two Li-Ion batteries.

Thanks again for the help!

[Crystal Chambers]

If you want to do two luxeons remember they need heatsinking which can take up valuable space. I've yet to see anyone use a Lux for a crystal chamber. Most 5mm when driven properly will do just fine and the ultra bright clear ones are available in most of the basic colours.

[boshwan527]

I feel you on the heat sinks. I think I have a way to make it work. Do you think a lux would be TOO bright? I was thinking about using two so I could match both of the colors. I was thinking about going with the deep red. Maybe I can find a 5mm with the same color

[Ronan]

If you want to do two luxeons remember they need heatsinking which can take up valuable space. I've yet to see anyone use a Lux for a crystal chamber. Most 5mm when driven properly will do just fine and the ultra bright clear ones are available in most of the basic colours.

For my graflex crystal chamber/chassis i had 2 5mm's, which was way too bright. I chose 1 5mm and 1 3mm which was brighter than needed but i went with that.

A lux for a crystal chamber is simply insane and potentially dangerous to bare eyes.


I feel you on the heat sinks. I think I have a way to make it work. Do you think a lux would be TOO bright? I was thinking about using two so I could match both of the colors. I was thinking about going with the deep red. Maybe I can find a 5mm with the same color

Theirs a TON of options on the web for 5mm's and 3mm's. I was able to match a Cyan Bin 1 to a chinese 5mm LED and a thai 3mm LED, both 'blue' but in fact had the right hues to make it look 98% the same to the naked eye. Cyan is a pain to match also, red will be much easier.

[Crystal Chambers]

A lux flooding an entire blade with light will appear dim next to a little chamber when also lit by a luxeon.

If you're really picky about colour you can always try the red coated, clear ultrabright, or even use some stain glass window spray or other translucent paint to tint a white LED. Otherwise most reds have some orange tint. I haven't tried the rebel yet but my LEDengin deep red still has some orange tint. It should be an easy match really.

[boshwan527]

Yeah good call. I guess I got a bit overzealous there haha. I just googled "deep red 5mm led" and found some so I'll just give it a shot. If they don't work I'll try some others. Those LEDs are cheap enough I guess. Man, I feel really lame....I'm supposed to be an engineer (mechanical at least), but the thought of stringing two LEDs together seems totally foreign. That's what I get for going to a research based institution. Too much theory... *sigh*

anyways...I should have a lot of time on Friday to actually get into the shop and make some more progress on the saber itself which I'm really excited about. Too much electronics talk for one week.

I really appreciate all of the help. Once people tell you these things it seems so easy and clear and it all makes sense. I imagine a lot of people go through that though. I'll keep you guys posted :)

[Ronan]

Man, I feel really lame....I'm supposed to be an engineer (mechanical at least), but the thought of stringing two LEDs together seems totally foreign. That's what I get for going to a research based institution. Too much theory... *sigh*

It's all like that now. They are more interested in your $, idiotic tests that are mostly useless out there, and theory. But once its time to apply it at work... DURP DURP DURP...

Don't waste your money on a bachelor, get a cheap one, then get a good master. Thats what counts now a day. It's different for engineers though. Here its 5 year study which is equivalent to a 4 year Bachelor but you get an engineer title. Kinda like a Bachelor/Master, not quite each, not quite both.

[boshwan527]

Yeah I already got my Bachelors and I'm doing my Master's now. My program is only a year long though. So in 5 years I get both, which isn't too bad. To be fair I'm pretty good at ME stuff, but they make us take intro to EE and that really didn't do anything for me haha

[Crystal Chambers]

Cool..looking forward to seeing what all this training will enable you to bring to the saber scene. Future builds etc.

[FenderBender]

We used the Kingbright 5mm clear reds for our Starkillers. They are crazy bright like 20,000MCD or something and a nice shade of red too. Mouser sells them.

[boshwan527]

I got most of the emitter section done. It looks simple, but it took me like 6 hours because I haven't used a lathe in a while...hope you like it. I probably won't get a chance to work again for another few weeks. School is really picking up with projects and everything :(

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00264.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00265.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00266.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00267.jpg

[boshwan527]

not a saber update, but I just got engaged and I'm super excited!!!! so I'm telling the whole world:

http://i924.photobucket.com/albums/ad90/boshwan527/0850a0bc.jpg

...the force is strong with this one!
:D

[Knighthammer]

Congrats!
Going on 13 happy years myself.

[CGompertz09]

Congratulations on the engagement!!

[boshwan527]

Alllllllright!!! Back at it :) Spent 4 hours in the shop today and here's what I got done. I had to do some weird stuff to make room for the button as you'll see. I'll get some more pics with the internal cylinder I machined eventually, it's just really snug so I need to hammer it out.

let me know what you think :)
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00338.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00339.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00340.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00342.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00343.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00344.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/98c26f68.jpg

[Crystal Chambers]

Hey Congrats!

nice work but you really got me scratching my head. The whole need for the internal is for the graflex pins? I don't see any room for optics. Is this going to have a string blade?

[boshwan527]

Yes and no. It holds the pins, but it also holds the glass eye and the whole emitter itself. There really wouldn't have been room in there for anything else anyways. I'm putting a rebel star in the actual emitter section with a blade plug. I don't think a blade would fit, but that's ok with me. My goal was always to build something that looked like I wanted it to, without sacrificing anything to make it "functional". It was always intended to be a display piece with some LEDs here and there. My next one though I'll go all the way. :)

[boshwan527]

Anyone else feel like pics never do sabers justice? :( I wish I could show you all in person haha

[Crystal Chambers]

Even for a display piece I'd put a string blade in it. It just seems like a lot of work not to have some type of blade. I normally prefer Lux type LEDs for my blades but for a display piece strings look great and they open up more options in the BH section. As long as you can fit the blade stock it's just a matter of soldering a bunch of 5mm LEDs inside some foam.

[boshwan527]

So I was lookin into doing a blade (never really had before) and it should work just fine withe the setup I have with the rebel star :)

[Ronan]

Very nice work. I'm not a fan of the ears though.

Don't worry too much about blades... Usually you show it once or twice with a blade in and then it stays on a shelves on display w/o a blade because you end up running out of place too quickly :D

[boshwan527]

Small update for today:

I got the pommel done. It's a simple piece, but still took a fair bit of time. I'm still not too quick on a lathe.
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00351.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00352.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00353.jpg

All i can say after taking this project on is the Jedi temple must've had one heck of a machine shop

[boshwan527]

I did some crystal chamber design today...I think this is what I'm gonna go with. You'll see some obvious similarities to Sloth's work. I hope he takes it as a compliment :D

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/CC1.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/CC4.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/CC2.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/CC3.jpg

[Ronan]

I wish we lived closer, we would have so much fun :p :D

[slothfurnace]

I did some crystal chamber design today...I think this is what I'm gonna go with. You'll see some obvious similarities to Sloth's work. I hope he takes it as a compliment :D


I do! Nice work!

[boshwan527]

Thanks Sloth! glad you like it :)

Small update:

I made all the little brass spacer and the crystal holder thingy:
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/7a9696d3.jpg

[fau-pa ramid]

i am defiantly liking the way this saber is turning out. i am glad you are starting to post stuff up again. i have been waiting to see this one finished.

all these sabers with the crystal chambers and cooling fins are very sweet looking. i think this trend (for lack of a better term) is going to be the tucked engine bays of the saber world.

[boshwan527]

Thanks! it's good to have some free time to get into the shop. I hope it lasts long enough for me to finish this semester because I graduate in may...then no machine shop :(
I wanted to get in two more sabers too, but I don't think that's gonna happen unless they're way simpler...which isn't my style haha

Anyways, after machining the crystal holder, I don't like the bar down the center. After putting the crystal in I think I'm gonna spin it 180 degrees. It looks like the center ring is floating and I think it looks cooler:
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/27e7ebcf.jpg

[boshwan527]

Woohooooo this is the post I've been waiting for. I made a ton of progress on the crystal chamber

Cuttin me some disks on the lathe
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/b793bda4.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/441491cd.jpg

All rigged up:
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/c35ac75a.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/77573e57.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/93830c33.jpg

And building:
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/3a2e5374.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/a763182c.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/597df0ad.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/4762edd6.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/becfd670.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/43fe2b39.jpg

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/25c38c03.jpg

Now it BARELY doesn't fit in my hilt so I have to hit it with some sand paper tomorrow before I can get some pics of it all together. I also need to drill some holes for the end caps and do a little tapping here and there for set screw. Other than that I have an end in sight!

p.s. does anyone know of a good anodizer for saber parts?

[fau-pa ramid]

very clean. i am glad you got to get this part all banged out. looking forward to seeing this in the saber. -Pat

[Rafalema]

Magnificent work. Keep it up! :cool:

[Jedi Mynock]

AWESOME!!!
and wouldn't you know it, i just started working on my MFX starkiller (again) about a week ago. ;)
my chamber wont be nearly this detailed though!
NICE WORK!!!
I hope your string blade works out. this saber NEEDS a blade!

[boshwan527]

Thanks everyone :D

Two updates in a row! I'm in fireeee haha I did some clean up work today and did the endcaps for the chamber.

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00358.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00354.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00355.jpg

and with the plain rails in. I still need to do all of the notches, but I thought I'd throw them in and see how they look. I honestly think I might like it without the rails better. That could just be because I haven't looked at it long enough and there's no detail on them. We'll see I suppose
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00356.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00357.jpg

[dustunite]

this thing is coming out great, just went through this whole thread and start to finish it's awesome. I agree with crystal about the blade but either way I like it!

[Arryck Corso]

I love it when post new updates boshwan527. Between you and slothfurnace and a couple other sabers I've been following, you guys have really motivated me to bring my "A" game. The stuff you guys are showing can be done is both intimidating and inspiring. And it's really helped me push the original boundaries for my design.

I totally understand you about the school thing too. I've been so busy lately writing papers and studying for my different exams that I don't feel like I'm getting anywhere at all on my saber. It'll eventually get built though. Anything good worth having doesn't come easy.

Keep up the great work!!!!

[slothfurnace]

Excellent work! I would be very proud to have this saber in my stable. Love what you have going on so far. Keep it up!

[captain_mills]

WOW! Way cool crystal chamber! I love the twisty cable channels on the back side. As said before, very clean and nicely done!

[FenderBender]

Nice work. As far as anodizing, you won't find one willing to take on a single project. It's just too costly for them. I would look around on hackaday and see if you can find the DIY anodizing instructions.

[boshwan527]

Thanks for all the kind words everyone!

THREE updates in a row!! woot woot!
So I machined the chamber guards and rebuilt the whole chamber (what a pain!!) And I put everything together, so this is basically what it's gonna look like except with the black anodizing.

I have to say now that those rods are actually machined and in there properly I like them :)

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00363.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00362.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00361.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00359.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00360.jpg

[Impa]

Most excellent work! Looking forward to seeing more.

[boshwan527]

Today I finished the last machining I had to do!! Woohoo!

First I tapped the charge port. This also serves to keep the grip sleeve in place:
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/9d4c14e7.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/9f7cea54.jpg

So the entire build...the thing I was having the most trouble with was how to secure the pommel without using visible set screw. So basically what I did was make a disk to pass two 4-40 screws through. This disk sits inside the main tube and is held on by two set screws. These set screws are then covered by the grip sleeve. The grip sleeve is then secured with the charge port. Then the pommel is inserted and secured with the screws that pass through the disk (using a REALLY long screw driver haha) I then milled a big slot in the pommel to give the charge port room. This worked out perfectly :)

http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/431a98c7.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/dfffd494.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/34cdb0b5.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/8fb589fa.jpg

And here's the whole thing all together! Not much different than before because most of the updates aren't visible, but still cool!
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/196c14c4.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/a38526cb.jpg

Tomorrow I'll be sending parts to Russrep to get them anodized, and that just leaves the wiring

Almossssst Theeeerrreee!!

[Boj-Vaati Mau]

Pretty slick and some neat work arounds. Keep at it, mate!

[Jedi Mynock]

note to self: never look at amazing threads like this while taking a swig from my morning monster. it has now run out of my gaping mouth.

AWESOME!!!!!

love the pommel! i need a better one now. the pressure fit sink cap of the MFX is embarassing lol
you intend on making a covertech "kill key" to stick in the charge port? that would be perfect.
im going to upgrade the "covertech" on my MFX to a TCSS black machined version, tap it for momentary switch #20 (sold out now but i nabbed some way back in like 2007) instead of the huge "basic" switch it came with.

your chamber is incredible. and yes, the guard rods are "groovy" ; )
and i was thinking of how to hide some wire guides behind the crystal, and you seem to have figured that out quite nicely! VERY well done!!!

come onnnnnn TAX RETURN!!!! daddy needs a set of red button/glass eye thumb screws!
("re"build thread coming soon for me. i hope!)
glad to see starkillers arent fading in popularity. they really are unique and interesting designs. i love how we have all put our own twist on them.
hmm... perhaps a signature graphic for starkiller owners similar to the "LUKE V2 CLUB" is in order? ; D

[fau-pa ramid]

very nice work. this is going to be such a nice saber when its all finished.

[boshwan527]

thanks so much guys! I really appreciate it!!



you intend on making a covertech "kill key" to stick in the charge port? that would be perfect.
I've thought about it, but the covertec might actually be too big. I think it has a 3/4" diameter so it would hit the pommel. I might make a smaller one for looks, but it wouldn't fit a belt



and i was thinking of how to hide some wire guides behind the crystal, and you seem to have figured that out quite nicely! VERY well done!!!
Thanks, but I can't take credit for that one. I got that idea for slothfurnace's vader build
http://slothfurnace.com/sabers/ANHVader_05.html


hmm... perhaps a signature graphic for starkiller owners similar to the "LUKE V2 CLUB" is in order? ; D
that would be awesome!

[Garrek]

That crystal chamber is awesome, Its my favorite I've seen so far.
How long is it? I'm thinking 2 inches, but just curious.

[boshwan527]

thanks man :)

It's actually around 2.5"

[Garrek]

ah, always so hard to tell with pictures.

I've actually never cared for starkiller sabers till yours, the chamber really makes a difference.
Can't wait to see it lit up.

[Jedi Mynock]

I've thought about it, but the covertec might actually be too big. I think it has a 3/4" diameter so it would hit the pommel. I might make a smaller one for looks, but it wouldn't fit a belt


you could always shave a bit off the base of a TCSS covertech wheel so it fits real snug against the pommel. ;)
i wouldnt trust a kill key CT wheel to actually hang my saber from my belt anyway. thats why im going to use a TCSS CT wheel to hide my momentary activation switch #20 and that will hold it in place.

who do we contact for the signature graphic? I'm so down for that! (and i need to finish my starkiller - PRONTO! my tax return mails today!!!)

when do we see some electronics in this bad boy?

[Jenny]

thats why im going to use a TCSS CT wheel to hide my momentary activation switch #20 and that will hold it in place.

Oh! Pictures, please!

[boshwan527]

I have to wait for the parts to get back from Russ (anodizing). I have to pass most of the wires back and forth through the CC so I need all the parts. I started soldering some little stuff but nothing noteworthy to show yet. I did test the led with the blade plug and it looks really cool. I'm really happy with the color. I also put an accent LED in the Crystal tube and I'm not sure it'll be bright enough so I'm gonna do two (one on each side of the crystal). Maybe that'll be too bright but we'll see soon. I can't wait til I get my parts back

I too would love to see the switch setup you described :)

I've also started working on my next build. Which will be the satele staff (ala slothfurnace :-P) I only have two months to build it before I lose my shop access though so hopefully I can get it done. I'll start a new thread on that one soon :)

[Jedi Mynock]

i havent made the "covertech switch" yet, cuz uh... i still need to order the wheel lol
but its pretty simple, really.
just drill a hole in the hilt where you want the CT, no bigger than the threaded area of switch #20.
drill a hole one size smaller in the CT wheel.
thread the hole in the CT wheel (thread specs are still on the measurements of sw#20 in the store)

VIOLA! momentary covertech switch! (sure you will see the button, but you can sand it down a bit so it isnt obvious)

;)

all i ask is you give me kudos if you use it, like say "Jedi Mynock CT wheel button" or something. 8-)

best of all, if you do it right you could probably still use it to hold it on your belt!

[Darth Maxis II]

Cool! keep the good work coming!

[jin starkiller]

This saber is turning out great .....got one of these in the works myself .......looking forward to the completed version

[boshwan527]

great news! I got my parts back from Russ. Here are a few teaser pics...I have to do some soldering/wiring though. It should be 100% complete by monday or tuesday!! :D
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00380.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00381.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00382.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00383.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00384.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00385.jpg

[DemonBunnyman]

probally the cleanest crystal chamber ive seen yet, Kudos to a awesome build

[Arryck Corso]

Wickedly cool boshwan527!! I'm totally jealous. ;)

[boshwan527]

So I have some great news...and some not so great news.
I spent a long time getting everything all wired up and it worked perfectly...except I couldn't get the wires to fit in the emitter :( I tried for quite a while...and I got fed up and wanted to see it together so I clipped the wires and put it together. I'll tackle the wiring again at a later (undetermined) date haha

here are some pics...I kinda went nuts to just get a bunch of angles so there's probably some duplicate angles...but I hope you'll enjoy them anyways :-P
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00395.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00394.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00393.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00392.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00391.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00390.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00389.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00388.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00387.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00386.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00404.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00403.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00402.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00401.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00400.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00399.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00398.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00397.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00396.jpg

[boshwan527]

So I went to bed last night and I couldn't sleep for a while. My joy at finishing this build after a year and a half was sucked dry with the thought that I completely failed at wiring it. Eventually I got to sleep and I woke up this morning and said to myself...."this is gonna happen"

It wasn't easy...and it certainly wasn't pretty...but:
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00405.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00406.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00407.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00408.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00409.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00410.jpg
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00411.jpg


My cheap camera makes it look pink...but It's definitely deep red. I'm gonna borrow my friends DSLR eventually and take so real nice pics. I also had to take out the second chamber LED because I just didn't have the room in the emitter end. So it's a little dimmer than I'd like, but sacrifices had to be made haha


...it feels good to finish my first saber...but it's almost a little sad because it was really about the journey *sigh*

[Obi-Dar Ke-Gnomie]

Congratulations, it looks good! It's a nice feeling to finish a saber and light it up for the first time. The good thing is that the journey doesn't have to end. Build on the skills you learned from this saber and build something a little more challenging, and keep growing.

[Dark Jedi]

It looks amazing... Your hard work has certainly paid off ;)

[YoRn Mangers]

I've been following the build since you started. And I have to say the final product looks amazing! Looks like something straight out of a movie. Cant wait to see how your staff turns out either.

Are we gonna get to see it with a blade?

[Repentance]

My god that is amazing, your first saber?!?

[zeropiccolo]

Overall a clean piece, but that crystal chamber is wicked :shock:

[boshwan527]

Thanks everyone! Your kind words mean a lot to me :D


My god that is amazing, your first saber?!?
..Unless you count the sink tube one I made when I was 12 from the bigyellowbox site haha!

[ARKM]

Very nice saber.

[boshwan527]

Thanks Tom!

I did some photoshop work (for the first time) and forgot to post them here.


http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00387_PNG.png
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00391_Blur.png
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00396_PNG.png
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00404_PNG.png
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00405_PNG.png
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00405-1.png
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00405_BW.png
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00405Blade2.png
http://i924.photobucket.com/albums/ad90/boshwan527/Starkiller%20Saber/DSC00405Blade.png


I was just trying out different things with that last one :-P