Build Log: First MHS saber

[Mav750k]

It has been a long time of careful planning and designs. Tim was kind enough to let me create all of the files myself. I almost feel like I should have paid him extra for having to sort through the mess of someone else's prep work. I have to say that his work on bringing this to life has been amazing. He spent some serious time going over everything to make sure it was right on. Great guy.

Here is the basic hilt, mostly as delivered yesterday. The only work by me has been some drill/tap work and cutting/fitting the inner aluminum chassis to fill the grooves Tim cut into the main body. Thanks again Tim!
http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120810_175104.jpg
http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120810_175117.jpg
http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120810_175202.jpg
http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120810_175140.jpg

[Mav750k]

There is still a bit of work to fit the middle ring on the shroud.

Here are some images of my prototype from a long time ago...

http://i747.photobucket.com/albums/xx120/Mav750k/DSCN2148.jpg
http://i747.photobucket.com/albums/xx120/Mav750k/DSCN2149.jpg

[Mav750k]

As you can see, the pommel is meant to ressemble an Obi Wan prequel style. The entire saber is a combination of Qui Gon/Obi Wan. I have some square aluminum to cut and attach to the pommel. That is still on the to do list. I prewired all the electronics to get everything working correctly. I butchered an econo saber, and made a rechargeable battery cell. Everything is working great, and I am getting some awesome sound out of the econo board with the premium speaker. Now I have to get everything to fit inside the chassis for install.

[amwolf]

Beautiful saber with some sweet details! VERY interested in how you're going to attach that middle ring - is it connected to the switch bevel or just butting up against it? Don't forget to shave those screws down on the blade holder to make sure the blade fits in (they look a bit long at the moment). No chance you'll wait for a Nano Biscotte and ditch that econo board?

[Mav750k]

There is some finish work for the middle ring to finish before attachment. I won't be relying on any one method of attachment. First, I need to notch the switch bevel so that it will overlap the ends of the ring. Then I will slightly pinch the middle ring, so that there will be spring tension to grip the main body. It will finally be positioned with epoxy to permanently position it. And, if I am still not satisfied, I will drill/tap several holes in it for 8-32 set screws that will thread in flush to the surface with locktight.


Here are several images from the assembly drawings of the files I made that Tim used to machine from. The pommel more closely resembles my intent in these renders. At this time, I was toying with the idea of using an extension at the bottom of the main body. I have since decided to stick to the original length.
http://i747.photobucket.com/albums/xx120/Mav750k/Finished6.jpg
http://i747.photobucket.com/albums/xx120/Mav750k/Finished1.jpg
http://i747.photobucket.com/albums/xx120/Mav750k/Finished4.jpg
http://i747.photobucket.com/albums/xx120/Mav750k/Finished3.jpg

[shmoetech]

Very nice, when are you going to show lit up? very Qui Gonish.

[Dahi Esmeva]

Wow thats a sweet saber. Can't wait to see it finished and lit up!

[Batosai]

really nice shroudework! especially I like the ring around the av-switch.

[Mav750k]

Thanks! I still have work to do on the inner chassis before getting everything lit up and humming.
I am also still on the edge of what color LED for the final install. Though my original intention was red, I have am currently leaning toward blue or green. She is turning out to look much too elegant for a sith saber.
I am all for getting a Nano Biscotte board when they become available, however I intend to work with what I have at the moment. It will be fairly simple when the time comes to make a second chassis with different electronics.

[Mav750k]

Poll added to thread for main LED color. Not saying it will be the deciding factor, but it will be nice to see what everyone thinks.

[Darth Ryo]

I like your saber very much, impressive work.

As for the blade color, I voted red like your first intention. I don't think it is too elegant for a Sith saber, on the contrary, I would even see that one on the Sith Council ;)
Beautiful !

[amwolf]

Can I put in a vote for Amber for the blade? Not on the poll but call it a write-in...

[Mav750k]

Blue was the early favorite, but it looks like red has pulled out in front!

Sorry amwolf, I am a sucker for the more iconic blade colors I grew up with.

Thanks for the compliments everyone, she is a labor of love. I debated spending the time on this, and just buying a Phaeton from Parks Sabers. Cost is comparable, depending on the internals. I'm definitely glad I went with my own designs, and I can't thank Tim enough for pulling them off so flawlessly.

I'm afraid there is't too much work getting done this weekend, the weather is way too nice to stay inside around here. The Harley just calls to me...

I might ask Tim to make me some more of those main body sections and shrouds. They would make some epic grips on the Hog.

[Mav750k]

Wiring and chassis completed. I will update with pics when I get them. So far so good. Still debating the color choice for the main led. But I'm considering making an interchangeable set of heat sinks to swap colors. I will probably go with red for the initial install though. Look for updates coming soon!

[clahey83]

if youre still undescisive for blade color here is an idea im working on for my next couple of builds. if your setup isnt going to have a flash on clash feature you can get one a RGB LED. tim just started carrying the tr-rebels and those will fit the bill. i found a little 3-position slider switch. you can mount it inside of your chassis somewhere and wire one die to each position on the switch and resistor each die properly between the switch and the die.

if your setup WILL have flash on clash there are the LEDengins. the one i am considering for my builds if i end up with FoC is the RGBA. its the same concept as the tri-rebel setup except the amber die is wired for the flash on clash. your saber would honestly look amazing with any of the 3 main colors, and this plan would make all 3 available to you with just the flip of a switch.

one thing to look out for though is if you install a sound card with a voltage regulator (like the petit crouton or crystal focus) you will not be able to change colors unless the kill key is inserted.

my other idea switch-wise is to find a small rotary switch with a decent knob and mount it into a hole drilled into the hilt. that will make the simpler setups able to change colors while already running (the Nano Biscotte that will be out soon will be able to use this feature as it has no voltage regulator) i have yet to find a rotary swith that fits the bill though, but im sure they are out there

i dont mean to sound pushy because this saber is your baby. i just thought i might share this with you and see if you like the idea.

[Crystal Chambers]

Cool! Reminds me of my Annihilator hilt a bit. I like your deep grip better though.

[Mav750k]

I have seen some RGB sabers built with switches for each color, and am not interested in adding knobs everywhere. The rotary switch would streamline that system incredibly. This demands more research. Thanks for the suggestion.

Just looked up the Annihilator. Very cool. The influences are undeniably the same. I like your approach to the same concept! I feel a bit more pressure to get this done right. These 2 sabers would look great next to each other.

I think I'm going to stick with a red LED for the econo chassis. But the research commences for an RGB set up when the new board is available! Thanks again clahey83.

[Jay-gon Jinn]

If you're really unsure of what color you want, you could also add a JST connector to the led and board and simply swap out the led....you'd need another led and heatsink to do this, however, which would add to the cost of the build. The Hasbro Economy, or toy sound boards do not have an led river like the CF and PC do....a rotary switch set up will work fine with that board if that's what you're using.

[Mav750k]

The JST\separate heat sink assemblies was my original plan, and I am continuing with it for the econo board setup. I have one assembly for each of the 3 colors. Right now I have everything working correctly, I just have to work out some clearance issues with the switch and resistors. Since each color requires a different resistor set up for the juice I am running through the cheapo board. Anybody know where to get some micro resistors smaller than the ones available here? I plan on putting much more effort into the next chassis and electronics when the new boards arrive. If I am fast enough to snatch one up before they sell out, that is. Looks like they will be selling like hotcakes. No pre-order list, correct?

[Jay-gon Jinn]

No, no pre-orders for the Nano Biscotte....it will be a regularly stocked item, and if it sells out, it will likely be back in stock a couple weeks later, if not sooner. For electronics not found in the store here, all I can say is look online for electronic components distributors.

[Mav750k]

I only ask after searching for a few days already. I have some that look like a bit different shape on order, but it is the internet, so who knows if they will be any different than the set from Tim. In relatively new to this level of electronics, so if anybody has some search keywords for what I need I'm all ears. I've tried combinations of: mini, micro, tiny, small, compact resistors worth the stats I need included. I appreciate the help. You guys have been an awesome resource for me on this. I really haven't had to ask questions so far with all the great info and tutorials here on the forums, despite my complete lack of knowledge getting into this. Sorry for any typos and the wall of text, stupid "smart" phone.

[Mav750k]

Pic update!

The blue and red led setup with the old hasbro economy board:
http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120818_220052.jpg
http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120816_204440.jpg

I am currently wiring a Novasound nutrino for a cleaner looking chassis. It will also allow me to eliminate the resistors from the main LEDs that have been limiting my interior space.

And the work so far on the pommel trim pieces:
http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120913_002353.jpg
The scorpion next to it is the first design I made on the computer. It is 1 solid piece of sheet metal, laser cut and folded into shape.

[Mav750k]

I will update with wiring pics and some close up shots of the individual components when I make the time.

[shmoetech]

I'm glad that u did the blade blue it looks much better than red.....what! sorry sith spawns

[Mav750k]

Right now with the nutrino, I have a red, green and blue LED depending on my mood. I'm currently scratching my head at the new board's behavior with the AV switch. Anyone else use the same board/switch combo?

[Mav750k]

Nevermind. Problem solved. Loose solder

[Mav750k]

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120925_125719.jpg

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120925_131012.jpg

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120925_131127.jpg

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120925_123726.jpg

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120925_130211.jpg

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120925_130820.jpg

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120925_123739.jpg

[Mav750k]

I had to integrate the lens into the blade, and used the new style heat sinks to make up for the lack of space between the switch and the led assembly. This combined with the Novasound Neutrino board, which eliminates the need for a resistor on the main LED, makes the interior much more streamlined and easier to manage. I wish that I had taken the time to upload pics of the chassis before I installed it, as I am quite proud of the differences between version 1.0 and 2.0

[shmoetech]

Looks really good Mav.....Impressed i am mmmmmm.

[Darth Ryo]

I must say I'm impressed as well ;)

I'd have loved to see that chassis of yours, you didn't take any pics or just didn't upload them?

[Mav750k]

Thanks for the compliments guys! As far as pics of the chasis, I didn't take any. I was too focused on getting her back together. Luckily, version 2.0 is much easier to remove than the first one. I'll take her all the way apart and grab some pics in the morning.

[Mav750k]

Version 1.0, econo board. Just thrown together in excitement.

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_123258.jpg


Version 2.0 in pieces:

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_114953.jpg


Here is a pick of an unmodified speaker holder next to the one I made to fit inside the chassis:

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_115126.jpg



I made a square adapter out of sheet metal in order to attach the speaker holder up to a dremmel tool, and use a file on the outside edge:

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_115336.jpg
http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_115420.jpg

To get this result on the profile:

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_115257.jpg

[Mav750k]

Li-Ion battery in some cut and filed chassis parts from the saber shop:

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_115522.jpg

Inside new sleeve:

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_115600.jpg

Speaker attached:

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_115649.jpg

Next comes the board, wrapped in electrical tape to prevent grounding on the metal chassis:

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_115712.jpg
http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_115752.jpg

[Mav750k]

Now to plug everything in:

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_120134.jpg

[Darth Ryo]

Thanks for the photos ;)

Interesting and nicely done!
(I'll keep in mind that idea about modifying the speaker holder :D)

[shmoetech]

hey MAV looks good, quick question how does the metal chassis feel in saber? i used pvc myself, would be worried that there would be too much play in hilt causing metal to rub wires! if its nice and snug i'll just shut my mouth (just don't want anything bad to happen). besides that looks good.

[Dark Jedi 007]

Very very nice saber. Beautiful workmanship from TCSS as well. I was wondering where you got your internal metal sleeve? Thanx.

[shmoetech]

if i'm looking at it correctly.....i would say sinktube?

[MandoJoe]

Making my little nerd heart happy to see the 1701 in the background there. And is that a Saitek Joystick I see?

Also, now that I'm done admiring your other stuff, great looking chassis.

[Mav750k]

The metal chassis works out beautifully. I used some 1.25" sink tube that has a brushed nickel plated finish. I tried out 2 different brands, and one had a bit more play in it than the other. The speaker holder and the screw for the cover-tech clip holds everything in place very securely. Has a nice solid feel.

And yeah, that is a rather dusty Saitek Joystick in the corner. My mouse and keyboard are of the Cyborg line. I find them incredibly helpful. Not just while gaming, but also for running commands and fine detailing in drafting programs such as CATIA V5 and Inventor.

[Mav750k]

Here is a wider shot of the desk. Definitely more play than work, but I used the work excuse to the wife when I built it. If you can't tell, I'm a Darth Maul fan. Red and black is kinda the overall theme.

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120928_112835.jpg

Thanks for the comments guys! Right now I'm really enjoying enjoying having a fully functional lightsaber. And one that I designed and put together no less. My daughter thinks it is the coolest thing... EVER.

[shmoetech]

Nice set up Mav....

[Darth Ryo]

Always cool to see other people having the same kind ok geeky stuff ^^ nice set up indeed!
Also a big fan of red and black ;-)

I bet your daughter thinks that saber is cool... it rox really!