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Boj-Vaati Mau
05-18-2012, 02:41 PM
So I've gotten into this build the last few days as it took a bit to get all the parts togeher. The first image is the evolution of the design as Kali kept seeing different things she liked and took a bit to settle down on.

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/Currentcollection.jpg

She'd finally settled on the last design and I'd widened the Tail End Shroud. The copper will be baked on Hammered Copper from Rust-Oleum and I'll use upholstery grade vinyl for the green leather.

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/CsSaberFinalGreen.jpg

The process of getting up to where the shroud work is today.

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/Basicshroudwork.jpg

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4202.jpg



These weren't too bad to cut out. Most of the roughing was with a Shoe Maker's file then cleaned up with a 1/2 round Mill bastard and Finishing files, and finally sanded with 400 and 1000 grit sandpapers.

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4204.jpg

This was fun as I'd broken 2 fine and one coarse Jewler's Saw blades, cut a channel with a Tugsten Carbide router in my Dremel, drilled a batch of holes and then broke two drill bits cutting between the holes. The smoothing procees went back to the router bit. As you can see, I've got the back part cleaned up and finished so today goes to cleaning up the front.

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4205.jpg

And here's a color study of the copper, green vinyl, and aluminum.

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4206.jpg

Boj-Vaati Mau
05-18-2012, 07:46 PM
Here we are at the end of the day...

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4208.jpg

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4209.jpg

brett
05-18-2012, 11:07 PM
There looks to be a lot of work gone into this, and the results are great! Interesting and original design, will keep my eye on this build, thanks for all the images. Always inspirational to see what others are doing.

Boj-Vaati Mau
05-19-2012, 08:43 PM
Thank you, brett. Quite a bit of hand work when you don't have belt sanders and large drill bits! My wife is waiting as patiently as she can for it to be complete.

DemonBunnyman
05-19-2012, 11:20 PM
looking good :)

Nichos Seastrider
05-20-2012, 03:48 PM
Definitely digging it. Looking good!

Boj-Vaati Mau
05-22-2012, 06:24 PM
Thank you, gentlemen. I'd finished the drilling and tapping for the shroud work but stuck the Blade Holder soild on the third go round on and off. I'm waiting for the penatrating oil to work it's way through and hope to continue afterward. I did some damage to the grenade section so I've got more filing and sanding to do now. *sigh*

Noyl Wendor
05-22-2012, 06:36 PM
Wow, that is really taking shape, I really like the style you have going on this one ;)
Do lots of pics when you are done :)
Very nice work.

Boj-Vaati Mau
05-25-2012, 11:10 PM
Thank you, Noyl. I'll do a minimum of 3 at the end and a bunch in process. ;) I have the shroud work done, minus the Blade Retention Screw hole (Doh!), and will bake it in a couple of days. I decided to paint the brass Activation Switch Bezel copper...

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4234.jpg

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4235.jpg

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4236.jpg

With a little bit of Fotoshop Force it looks thusly...

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4234a.jpg

Nichos Seastrider
05-26-2012, 07:14 AM
So seeing it colored now, I really like how the pommel piece actually looks more like a full cap. Definitely digging the contrast between the green vinyl and the copper as well.

Boj-Vaati Mau
05-28-2012, 11:41 AM
Thank you, Nichos, I try. :) It took quite a bit of back and forth with my wife to get the style and colors down. She loves the look and the few changes I've made since were more easily received. ;)

Nichos Seastrider
05-28-2012, 02:16 PM
My wife is sort of indifferent toward what I've been planning as my first build here, but I know her well enough to know that once I get it finished she'll want one too. So I've been planning hers out as I go along.

Boj-Vaati Mau
06-05-2012, 01:05 PM
:) Mine keeps pointing out that she's a jedi in the UK so she has to have one, IMO! :D The band is cut so I just need some vinyl & rubber cement to mount it. Completed the pattern for the main grip and need to get a repair kit to patch up the pieces for that. Then it's cutting down a few screws for the emitter shroud and teh hilt will be complete. Then onto the electronics.

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4244.jpg

Boj-Vaati Mau
06-09-2012, 08:41 AM
External done, save getting a longer cap screw for the CoverTec button, on to the electronics.

http://i734.photobucket.com/albums/ww349/Jecull/General/2012-06-08_20-10-34_508.jpg

jedipwn27
06-17-2012, 07:21 AM
I really like the copper colors especially on the emitter shroud. Keep it up :)

Boj-Vaati Mau
09-06-2012, 03:41 PM
The joys of the real world getting in the way and spending too much time on contemplation of set up. I decided on two 6 wire plugs for this and this is the diagram I came up with;

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/Wiring.jpg

The wires that just seem to end at the PC go under the board to attach there. My plan is to epoxy the two male ends to a Buck Puck Chasis Disc...

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/Untitled.jpg

shmoetech
09-06-2012, 03:48 PM
Wow Boj. thar is a nice saber, really like the copper shroud....nice touch!

Boj-Vaati Mau
09-10-2012, 01:19 PM
Thank you, shmoe, it's been quite the journey. I was hoping to capture a basic saber, which is what my wife wanted, with some relatively feminine touches to it.

Here it is a wire routing prior to solder. The plugs hold nicely with friction, for the moment, and the wires are cut down to allow something to hold onto before finalization.
Still not quite sure what to do with the spare wire but at least it's there if needed.

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4300.jpg

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4301.jpg

MandoJoe
09-10-2012, 02:07 PM
Lookin' good, Boj. Very nice and neat.

Boj-Vaati Mau
09-10-2012, 04:48 PM
Thank you Mando, that's what I was shooting for. I did figure out what to do with that 12th, green wire...

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/WiringMkII.jpg

Putting in the JST will make for a completely seperatable module which was another goal I was aiming for.

Boj-Vaati Mau
09-10-2012, 09:43 PM
Here's where I'm leaving off for the night...

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4302.jpg

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4303.jpg

Boj-Vaati Mau
09-19-2012, 09:09 PM
Because it amuses me...

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/DSCN4437_zps4cbcf9d4.jpg

shmoetech
09-20-2012, 03:59 PM
Enjoying watching the progress...looking good!

Boj-Vaati Mau
09-20-2012, 07:31 PM
Thank you shmoe. I'm going to wire it up as it is to bench test then I'll work on routing the front half wires.

MandoJoe
09-22-2012, 12:30 PM
Still looking awesome. Loving the progress. Also, that last pic amuses me too.

Boj-Vaati Mau
09-23-2012, 04:10 AM
:D It's the Palm Tree of Light!

shmoetech
09-24-2012, 04:12 AM
It looks like Bleeper from the muppets. lol

MandoJoe
09-24-2012, 06:29 AM
Memememe! Me meme me me me! *chuckles* I saw it and immediately thought fireworks/can of "snakes" that just exploded.

Boj-Vaati Mau
09-24-2012, 10:56 AM
The joys of finding amusement in teh simplest of things! :D

Boj-Vaati Mau
09-25-2012, 01:32 PM
Got it all wired up and Presto! It's power Cycling! :confused: Not quite sure the issue and it only works with the charger engaged. :confused: For the sake of it here's the schematic again:

http://i734.photobucket.com/albums/ww349/Jecull/Lightsabers/WiringMkII.jpg

shmoetech
09-26-2012, 04:22 AM
Boj I wish I could help, but i can bearly see your schematic

Crystal Chambers
09-26-2012, 06:03 PM
odd...I agree it's hard to see your diagram but first thing I'd be looking at by the sounds of it is your port.

Boj-Vaati Mau
09-26-2012, 07:52 PM
Ach du Liber! Now ist UBERSIZED!

7712

Forgetful Jedi Knight
09-26-2012, 08:24 PM
Since I am walking in at the end of this... It looks like the grey wire in your switch is in the wrong place. It should be on the middle lug, not the one it is on. Also make sure you have the switch parameter set properly for that type of switch. It also looks like you have the switch pad wires wrong. The switch gnd is on the right, not the middle. The pads are marked.

Also, the PeX wiring looks wrong, and I don't see an aux switch. You may need to use some different colors on your PeX wiring. ;)

shmoetech
09-27-2012, 03:54 AM
fjk is on to something w/ switch (believe thats the long mom, switch), just had same prob. had to remove and do continuity test on it pressed and depressed.

Silver Serpent
09-27-2012, 05:11 AM
Since I am walking in at the end of this... It looks like the grey wire in your switch is in the wrong place. It should be on the middle lug, not the one it is on. Also make sure you have the switch parameter set properly for that type of switch. It also looks like you have the switch pad wires wrong. The switch gnd is on the right, not the middle. The pads are marked.

Also, the PeX wiring looks wrong, and I don't see an aux switch. You may need to use some different colors on your PeX wiring. ;)

Actually, the grey wire on the switch is correct. You need to move the brown wire on the switch to the middle lug. Switch pad wires are incorrect, as FJK said.

The brown and black wires from the PeX should be going to the + and - power terminals on the board, respectively. The grey wire on the PeX should be running to the FoC pad (see page 23 of the PC2.0 manual). You also need a resistor for the FoC LED.

Also, switch the two black wires on your recharge port. It's currently set to kill power to your batteries. You won't be able to recharge them with this configuration (and you may cook your board!)

Forgetful Jedi Knight
09-27-2012, 07:50 AM
Also, switch the two black wires on your recharge port. It's currently set to kill power to your batteries. You won't be able to recharge them with this configuration (and you may cook your board!)

Yes, now that I saw this on a better resolution computer, SS is right, the black wires are reversed on the recharge port.

Boj-Vaati Mau
09-27-2012, 09:06 PM
All right, thank you gentlemen and lady, I see where I bunged it up now. I should've checked the larger schematic for the AV switch as I'd wired it as a NC rather than an NO. Also forgot to add in the resistor on the PEx....Derp! Just messed up the routing on the RPort, should've checked that against the diagram in the manual. I was using this as a diagram for the FoC, is it incorrect for a PC 2?

7726


If not it's not a huge deal to wire it up thusly:

7727

As far as the Aux goes I didn't put it in as I've got to figure how to mount and actuate it first.

Forgetful Jedi Knight
09-27-2012, 09:14 PM
You still have the gray wire on the aux pad on the board. It should be on the gnd pad. Other than that, it's good. You should figure out the aux button sooner than later ;)

Boj-Vaati Mau
09-27-2012, 10:09 PM
I really should get in the habit of doing this type of thing in the afternoon on my days off. Working on this when I'm tired doesn't seem to work well. Now, after making the other changes, I get what you're saying about the main switch grey wire. Double derp on me! :rolleyes:

Forgetful Jedi Knight
09-28-2012, 10:32 AM
I really should get in the habit of doing this type of thing in the afternoon on my days off. Working on this when I'm tired doesn't seem to work well. Now, after making the other changes, I get what you're saying about the main switch grey wire. Double derp on me! :rolleyes:

Yes, another former (and infamous) padawan use to do this all the time and it NEVER, EVER went well for him. ;)

shmoetech
09-28-2012, 10:40 AM
Ha ha ha lol.

MrCafe
12-03-2012, 02:33 PM
Making me jealous. I can not wait to get space for a work shop so I can at lest try to make something and awesome as this saber. Nice colouring.

Boj-Vaati Mau
12-03-2012, 04:49 PM
Thank you, MrCafe, I do try. I've ordered the new Recharge Port and another PCB as those seem to be the probable cause it this saber not staying on. Kali has been very patient with me...