Custom Saber Build Log: Azaz'el

[cardcollector]

Hey folks,

Well, I am going to be documenting another step by step, showing how I make sabers. This commission is the largest I have ever done by far, with many, many, features.
So, with that, let us begin. ;)
https://lh6.googleusercontent.com/-plEgIYHAxo4/T0Et-a2PxZI/AAAAAAAABdg/CvpWUv35aMc/s833/saber%2520render%25203.jpg
Here is the render, as you can see, it will have a crystal chamber, dark weathering, and some other stuff. I will also be adding a full reveal chassis, so you can take the lower end off and see the inner workings. I will also be making a custom SMD LED bargraph. The same will be made to look like an ancient sith saber, so things need to look old, but still cared for. This is perhaps some of the most difficult type of weathering to do, as the interior must match the exterior... fun stuff.

https://lh6.googleusercontent.com/-w2w6gqhkCTw/T0Ewa5XJEhI/AAAAAAAABeM/BWEqkrJqGKo/s640/DSCN3590.JPG
So, the standard LED Module needed to be altered so the retaining washer can be placed to hold the reveal chassis.

https://lh5.googleusercontent.com/-PdeG1kfbiNk/T0Ewa464BSI/AAAAAAAABd0/4cngv5rZL4o/s640/DSCN3591.JPG
Took the top piece and sanded it down on the belt sander

https://lh3.googleusercontent.com/-IKYePhmfElg/T0Ewaxz2mmI/AAAAAAAABdw/vBu3VmCBiew/s640/DSCN3592.JPG
now the Retaining washer takes the place of the module lip I removed.

https://lh6.googleusercontent.com/-AXXWs79vIIk/T0Ewbfnf0RI/AAAAAAAABd4/v9pILBUTb_c/s640/DSCN3593.JPG
had to remove some material to allow the nuts to sit flush to the heatsink.

https://lh4.googleusercontent.com/-nN7BVr_ybAA/T0EwdKemTeI/AAAAAAAABeE/ZeU97jdW-fM/s640/DSCN3595.JPG
The TCSS Speaker housing didn't fit in the pommel, so I had to make on out of PVC. I will cover it in heatshrink after it is finished, so it looks nicer. ;)

https://lh6.googleusercontent.com/-HlCfFnFRtFU/T0Ewd8r1zNI/AAAAAAAABeQ/lcoeN8nYtcs/s640/DSCN3596.JPG
a little ring to allow the speaker some room in the pommel, better resonance.

https://lh3.googleusercontent.com/-NONks_BIDBI/T0EweJ9VGQI/AAAAAAAABeU/SItUJkkKJxI/s640/DSCN3597.JPG
I began to measure out dimensions for the chassis. This is what takes the longest time, as every bit of space is precious, and everything must fit in a certain way. You can see the crystal that will be used in the background.

https://lh5.googleusercontent.com/-3IPezYYPwSs/T0EweWaCOEI/AAAAAAAABes/Pq1aIAla2Pk/s640/DSCN3598.JPG
The two angled pieces measured and cut.

https://lh5.googleusercontent.com/-2FRfoh0gtio/T0EwepElJqI/AAAAAAAABeY/AvFGzsfC8bs/s640/DSCN3599.JPG
rough sketch of what we have so far.
Next main thing is to finish the chassis, align the outer parts, and drilling.

https://lh4.googleusercontent.com/-1dbv_Luza0k/T0Ewe0Rjy6I/AAAAAAAABec/KWJ1Lln5jEk/s640/DSCN3600.JPG
Can you guess what these are for??? ;)

That's it for now, I will probably be posting an update once a week. ;)
Any questions? Just ask. ;)

[Rafalema]

Sithgasm. Propably more to come. :cool:

[cardcollector]

Time to update this.

Gotten a lot of the internal planning out of the way, which I am glad of. the chassis is beginning to take shape, everything has its proper place now... So building should go much more quickly.

Last time I showed you some bronze pieces, I will start with those.
I always wanted to have some internal bling to a saber that represented the gyromotor, that controlled the balance of said weapon.

https://lh6.googleusercontent.com/-yq78MRG0F_c/T0pLisEhENI/AAAAAAAABgs/_G9sRBu23EI/s640/DSCN3614.JPG
Notches cut to slide along the rods...

https://lh3.googleusercontent.com/-K2-BnWiJTdo/T0pLmE10EgI/AAAAAAAABiQ/gsWx8ucFDo4/s640/DSCN3615.JPG
Drilled out a portion to mount the motor.

https://lh3.googleusercontent.com/-AGa1GMFuV1w/T0pLi5QFgdI/AAAAAAAABg8/HT04wYbMsY4/s640/DSCN3616.JPG
And the motor glued in place. It will not spin, but provide a nice look.

https://lh4.googleusercontent.com/-t4ElTeIm_QM/T0pLjK0tihI/AAAAAAAABhE/oQSV0py6GSM/s640/DSCN3617.JPG
Backlight with a blue LED, it will match with the bargraph.

https://lh3.googleusercontent.com/-SqVJGMYU8pE/T0pLjZWbXVI/AAAAAAAABhQ/y_nU8VQZ0LE/s640/DSCN3618.JPG
SMD blue LED soldered for the gryromotor. Toothpick tip for scale.

Moving on the the chassis...
https://lh5.googleusercontent.com/-0fJ14PFrauA/T0pLjc_NzAI/AAAAAAAABhU/-OM6hPGvca0/s640/DSCN3619.JPG
Concept for the crystal chamber, Probably will go with something like this with some copper somewhere...

https://lh6.googleusercontent.com/-cdXPlzhGIeQ/T0pLj9ngh5I/AAAAAAAABhs/zx29tsjnvFc/s640/DSCN3620.JPG
Test fitting the crystal.

https://lh6.googleusercontent.com/-YlBh8k-XXHc/T0pLj18UXBI/AAAAAAAABhg/q8gPCjDzjuk/s640/DSCN3621.JPG
This is the current state of the chassis. The PVC speaker module is also going to hold the Crystal Focus soundboard...

https://lh3.googleusercontent.com/-hZk_Aln9Ek0/T0pLkVpbh7I/AAAAAAAABh8/qAHZIfoJHxg/s640/DSCN3623.JPG
Like so.

https://lh6.googleusercontent.com/-VXq6eavin9w/T0pLkGijByI/AAAAAAAABho/5ecJnfTRoC0/s640/DSCN3622.JPG
A brass battery chamber for the 2 li-ion cells.

https://lh4.googleusercontent.com/-UzSoUsDdM4g/T0pLkTF07UI/AAAAAAAABh4/AQZxFZpj-yQ/s640/DSCN3624.JPG
Aaand some of the weathering has begun. ;)

[cardcollector]

Not much for this week, but still a little progress...

After making sure the Chassis was just how I wanted it, I moved on to the hilt.

https://lh4.googleusercontent.com/-MFh6n-CXYxM/T1OHK6NVW1I/AAAAAAAABjw/k8MF7P_kD-U/s640/DSCN3636.JPG
Here I marked out where I needed to mount the box on the 3" extension.

https://lh5.googleusercontent.com/-aXIQN9T0Fuk/T1OHLDnxqbI/AAAAAAAABj0/4_S6wDb_elk/s640/DSCN3646.JPG
Vised it up, and drilled out the material. Then I cleaned it up with a dremel.

https://lh4.googleusercontent.com/-QmO_FflR7jk/T1OHLEak6DI/AAAAAAAABj8/8FxbpU_UT4o/s640/DSCN3652.JPG
This shows the angled pieces cleaned up and test fit, and also the box installed. It is not centered lengthwise, as it being 1/4" closer to the emitter looked better.

https://lh4.googleusercontent.com/-MtTWqLM8GUc/T1OHLWHzKxI/AAAAAAAABkI/b464WEqL_W8/s640/DSCN3653.JPG
Better angle of the box installed. It looks really good!

Now to move on to some electronics... Specifically, the bargraph.
https://lh6.googleusercontent.com/-Dzlceewk1xs/T1OHVV1FBMI/AAAAAAAABkg/QSds58sJemE/s640/DSCN3637.JPG
Just some PCB.

https://lh4.googleusercontent.com/-JTN0RhrbBFI/T1OHVHkUxGI/AAAAAAAABkU/ORjx8530kzc/s640/DSCN3638.JPG
I drew out what I needed for the bargraph, and then cut it out.

https://lh4.googleusercontent.com/-Is1Wzfowzx0/T1OHVijCeOI/AAAAAAAABks/uLMLmPnLT1Y/s640/DSCN3639.JPG
Like so.

https://lh3.googleusercontent.com/-bqzgj5EEY-E/T1OHVgEJtoI/AAAAAAAABko/i1yxucbQG1w/s640/DSCN3640.JPG
Tinning the pads is key to making SMD soldering easy.

https://lh3.googleusercontent.com/-lZrYGaEAjZw/T1OHVztUlZI/AAAAAAAABk0/Hf_W_qQ5r4U/s640/DSCN3641.JPG
All 7 LEDs in place.

https://lh4.googleusercontent.com/-AtWCTOUQAbA/T1OHV_ZpWmI/AAAAAAAABlQ/xHmDlKGtaWw/s640/DSCN3642.JPG
Here you can see each have appropiate + wires, and share the common ground.

https://lh4.googleusercontent.com/-xfFpLbfue6Q/T1OHWABUTzI/AAAAAAAABlA/htyHypiafGw/s640/DSCN3643.JPG
Then I heatshrunk the thing for better insulation. No shorts here!

https://lh6.googleusercontent.com/-EWHZq2EehyI/T1OHWGnO8XI/AAAAAAAABlE/aFp9tQ2kQUE/s640/DSCN3644.JPG
OCD kicked in and I had to make sure the wires looked nice on the back too. :P

https://lh4.googleusercontent.com/-3F8I1mDJfS4/T1OHWUMLbrI/AAAAAAAABlc/PWJCbjj5XzA/s640/DSCN3645.JPG
And it works like a charm.

https://lh5.googleusercontent.com/-h_XU9Bs5kwU/T1OHWc2o5FI/AAAAAAAABlU/u_bOYEbWO94/s640/DSCN3647.JPG
Here is another SMD LED w/ resistor... It is for the gyromotor.

https://lh6.googleusercontent.com/-JtWvAF6G06o/T1OHWo7cRcI/AAAAAAAABlo/dGiWGR-LNe4/s640/DSCN3648.JPG
And glued in place.

https://lh6.googleusercontent.com/-myG3MFtq5_8/T1OHW9JXRZI/AAAAAAAABlw/3BkyQGVsUWY/s640/DSCN3649.JPG
Lastly, one more red SMD for the crystal chamber.

https://lh5.googleusercontent.com/-GHu4XMFdnT8/T1OHWxKuSrI/AAAAAAAABl8/YeR0u46NxEw/s640/DSCN3650.JPG
Fits nicely.

https://lh6.googleusercontent.com/-hd55Hlf6_04/T1OHW6VrdZI/AAAAAAAABl0/z9RQMXwN-iA/s640/DSCN3651.JPG
and all soldered up. 8)

That's it for this week.

[Jenny]

I await the next installment with glee!

[havoc64]

I too await the next installment...

[Ka'getsu]

Yeah... What Jenny and Havoc said:)

[noslenpar]

This is looking great. Love to see this kind of detailed build log, I've learned a lot already. Amazing photos too.

[cardcollector]

Thanks folks. :cool:

No update this week, not enough progress for another post IMO. Be looking for a nice one on Sunday. ;)

[cardcollector]

Time for an update!

So, the last two weeks I got a little behind due to some study work. Now however, the hilt is all finished and will begin installing electronics this evening.

https://lh4.googleusercontent.com/-_8EiSYMVftg/T1WPWU5JodI/AAAAAAAABoU/d5mGSWP_IS8/s640/DSCN3654.JPG
Switched out the location of the crystal chamber due to space constraints... Here you can see where I marked the aluminum off to cut it out.

https://lh4.googleusercontent.com/-8R5xwv8zbZI/T11B43iv77I/AAAAAAAABpA/quIdmQYRfLM/s640/DSCN3662.JPG
Vised up and ready to go to town with the dremel.

https://lh6.googleusercontent.com/-N1m4-X9Pybk/T11B4zvdRlI/AAAAAAAABpE/5QHt9fCBA3A/s640/DSCN3663.JPG
Clearly, it needs some sanding and filing.

https://lh6.googleusercontent.com/-MsY160ima-A/T11B46WdkRI/AAAAAAAABpI/yoAMQeGXr7M/s640/DSCN3664.JPG
Cut out the piece for the shroud around the box too.

https://lh3.googleusercontent.com/-dBH3gWZkOKM/T11B5PRZCbI/AAAAAAAABpY/5PdgwAk-CmY/s640/DSCN3665.JPG
The weathering begins...

https://lh3.googleusercontent.com/-hkrsnDhReBM/T11B5UxMdxI/AAAAAAAABpc/lpN1URDpwJ0/s640/DSCN3666.JPG
another piece done...

https://lh3.googleusercontent.com/-InhMUz2U54g/T11B5opr69I/AAAAAAAABpo/b9yo_K5HW8U/s640/DSCN3676.JPG
Got the blade retention screw drilled and centered...

https://lh5.googleusercontent.com/-O4tmVGCMVxU/T11B5kchgoI/AAAAAAAABp0/aN2PUgJVk_0/s640/DSCN3677.JPG
So, since aluminum black wasn't working on the chrome switch, I broke out some flat black enamel paint, some thinner, and did the switch by hand. Turned out perfect.

https://lh4.googleusercontent.com/-uB62bQPrFho/T2Z4OfwUFeI/AAAAAAAABq4/m61Q8jkBMeY/s640/DSCN3693.JPG
This 8-32 set screw will hold a shroud in place. Much better than just gluing it on.

https://lh6.googleusercontent.com/-7XrkMRFpE0o/T2Z4OQ122aI/AAAAAAAABrA/qjEVAzQzCps/s640/DSCN3694.JPG
You can see the other side of the screw... and the weathering after going over it with steel wool and water.

https://lh6.googleusercontent.com/-CXc15W-YOtQ/T2Z4O0O0ugI/AAAAAAAABrc/qw7hTOLWO0Y/s640/DSCN3697.JPG
Here is a teaser of the all the piece weathered, and then powdercoated with clear matte finish.

https://lh6.googleusercontent.com/-5C58IlHSpO0/T2Z4PSlysRI/AAAAAAAABrg/J27qfnXR2dI/s640/DSCN3699.JPG
Here a a zoom out without the box on the hilt.

More to come next week...

[cardcollector]

Six weeks into construction of this saber... reaching the homestretch.

The Client changed his mind on the Main LED setup, so I have to wait for that in the mail the next few days... So I will got some prepping wire work done.

https://lh4.googleusercontent.com/-VBIxJVwVdn8/T29aGjUi2rI/AAAAAAAABuE/NB4cCWwbxX4/s640/DSCN3703.JPG
Time to add some SMD resistors to the Crystal Focus v5.1....

https://lh5.googleusercontent.com/-TNu55SVRnxI/T29aG9I6MmI/AAAAAAAABuI/0SyvXLD7rlA/s640/DSCN3704.JPG
Done. Tiny little buggers aren't they?

https://lh6.googleusercontent.com/-Ym2ZeVT-gdE/T29aHXsJTVI/AAAAAAAABus/wmhFjnGp92U/s640/DSCN3715.JPG
Speaker all ready to go.

https://lh6.googleusercontent.com/-_LzESnp7vYQ/T29aHTcVrWI/AAAAAAAABuw/eAeGfrOGUmQ/s640/DSCN3716.JPG
the recharge port...

https://lh5.googleusercontent.com/-aUW81lZD_WU/T29aHkMfhFI/AAAAAAAABvE/hV-g0gZplG8/s640/DSCN3718.JPG
And the Aux switch....

So now, when the LED gets here, I will be able to slap the top section together, and beging final assembly of the Chassis... Wire up the CF. and she will be done.

Oh, and here is the hilt, completely assembled and ready for install.
https://lh3.googleusercontent.com/-Gx0sxlDHGQE/T29aGyy4s1I/AAAAAAAABuU/Jz7DG_XBUdE/s640/DSCN3712.JPG
https://lh3.googleusercontent.com/-kjfOLntKf5I/T29aHBPX23I/AAAAAAAABuc/1AoLIWhtiYg/s640/DSCN3713.JPG
https://lh4.googleusercontent.com/-09sU6zgRlh0/T29aHHXQC6I/AAAAAAAABuY/POUxtXw7TgI/s640/DSCN3714.JPG

[Knighthammer]

Looking really good!

[Xanatos1986]

May I ask how you disassembled the AV switch and assemble please, I would like to add to knowledge.

[cardcollector]

May I ask how you disassembled the AV switch and assemble please, I would like to add to knowledge.

All you have to do is remove the metal lip around the base of the switch, and the entire assembly slides right out. I just glued it back together after the weathering. :)

[StickStickly]

How did you accomplish soldering those tiny SMD resistors? And what is the pad in the middle that looks to have solder on the pads but no resistor ? Im talking about the one next to the Accent LED ground pad. Do you have to bridge that too or is there just solder on there for no reason ? I would love to know so I dont mess my CF up. Thanks

Terrific work by the way ! Very interesting build !

[boshwan527]

Man that's a sweet build. I love that middle section with the ribbed section/angled sections. The weather also looks really good :)

[cardcollector]

How did you accomplish soldering those tiny SMD resistors? And what is the pad in the middle that looks to have solder on the pads but no resistor ? Im talking about the one next to the Accent LED ground pad. Do you have to bridge that too or is there just solder on there for no reason ? I would love to know so I dont mess my CF up. Thanks

Terrific work by the way ! Very interesting build !

That sir, is a loaded question. ;)
I have had three years of soldering practice first and foremost, on various boards and components. so experience really cam into play soldering those resistors.
Also, I have a good solder Iron. It is an anti-static $40 iron from MPJA. I bought some of the smallest tips, and work with that almost every day.

Then, I read the instructions in the CF manual, and went at it. Previously soldering the SMD LEDs helped some. You have to have patience, a steady hand, and use very little solder. I can't stress enough how important it is to keep a clean tip. I use a brass sponge, and it works the best IMO. A clean tip means instant solder flow.
Watch Erv's soldering tutorials too!

The empty space is an extension of the LED-, I was just going down the pads and didn't check till after to see what they went. :P

Good luck if you decide to try it out. Definitely the toughest solder job ever. If you can pull it off... you can solder pretty much any other saber related component. ;)