Bertuzzi
03-10-2012, 07:05 PM
Some time ago I sold a saber I used for stage combat (at least a few parts of it). As I wanted its new owner to be satisfied with the saber I rebuilt the chassis and wired everything again. He would be using this sabers in combat either so everything inside had to stay in place.
I started with a 32mm PVC Tube and a PVC profile.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_001_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_001.jpg)
Cutting out a huge window into the shortened tube.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_002_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_002.jpg)
Inserting the batteries into the holder and cutting a small PVC disk.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_003_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_003.jpg)
This disk is glued with double-sided adhesive tape on the battery holder. Now you see its function: it prevents the battery holder from sliding through the tube.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_004_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_004.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_005_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_005.jpg)
Another panel is made to hold the battery holder in place.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_006_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_006.jpg)
It prevents the battery holder from rotating.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_007_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_007.jpg)
I made a cutout into the panel to place the constant current source (1,4A) in it.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_008_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_008.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_009_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_009.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_010_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_010.jpg)
The current source and the panel are both glued with double-sided tape on the battery holder
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_011_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_011.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_012_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_012.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_013_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_013.jpg)
Now I had to trim the side of the tube which would be near the emitter so the switch would fit.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_014_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_014.jpg)
Then I wired everything up.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_015_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_015.jpg)
The whole interior, parts of the hilt in the background.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_016_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_016.jpg)
Finally, a few impressions of the finished saber.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_017_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_017.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_018_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_018.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_019_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_019.jpg)
http://saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_019.jpg
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_019.pg
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_020_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_020.jpg)
It not a spectacular saber but it’s quite robust.
Specifications:
- MHS-Hilt with flat black powdercoating
- Green and blue Seoul P4 LED, connected to the rest with a quick connector
- 1400 mA constant current source
- 4x 2000 mAh eneloop NiMH-battery
- 2,1mm Recharge Port
Hope you like it ;)
I started with a 32mm PVC Tube and a PVC profile.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_001_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_001.jpg)
Cutting out a huge window into the shortened tube.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_002_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_002.jpg)
Inserting the batteries into the holder and cutting a small PVC disk.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_003_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_003.jpg)
This disk is glued with double-sided adhesive tape on the battery holder. Now you see its function: it prevents the battery holder from sliding through the tube.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_004_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_004.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_005_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_005.jpg)
Another panel is made to hold the battery holder in place.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_006_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_006.jpg)
It prevents the battery holder from rotating.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_007_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_007.jpg)
I made a cutout into the panel to place the constant current source (1,4A) in it.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_008_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_008.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_009_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_009.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_010_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_010.jpg)
The current source and the panel are both glued with double-sided tape on the battery holder
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_011_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_011.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_012_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_012.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_013_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_013.jpg)
Now I had to trim the side of the tube which would be near the emitter so the switch would fit.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_014_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_014.jpg)
Then I wired everything up.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_015_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_015.jpg)
The whole interior, parts of the hilt in the background.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_016_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_016.jpg)
Finally, a few impressions of the finished saber.
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_017_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_017.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_018_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_018.jpg)
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_019_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_019.jpg)
http://saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_019.jpg
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_019.pg
http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/small/telian_020_small.jpg (http://www.saberproject.de/other/bertuzzi/Foren/lightsaber/Telian/big/telian_020.jpg)
It not a spectacular saber but it’s quite robust.
Specifications:
- MHS-Hilt with flat black powdercoating
- Green and blue Seoul P4 LED, connected to the rest with a quick connector
- 1400 mA constant current source
- 4x 2000 mAh eneloop NiMH-battery
- 2,1mm Recharge Port
Hope you like it ;)