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rogue9607
05-01-2013, 01:32 PM
So perhaps the title isn't the best, but I'll explain. A few months ago I picked up an old Logan 820 lathe and have been getting it back into working order. I finally turned my first piece last week, so that means it's finally time for a saber of my own! My wife gets to go to cons and troops with her Satele saber while I've been using a Mace MR. Not a bad option, but still... I need something better. And with Star Wars Weekends coming up, I need a saber without a blade for the parade.

Unfortunately, I've never used a metal lathe, so I wanted to do a test piece to get a feel for it before trying something more ambitious. When I bought the aluminum for my wife's saber, I got some extra in case I goofed and needed to remake a part. Thankfully, I didn't have to use any of that extra, so I set about designing something that I could make out of that scrap, hence the "scrap saber" title. If all goes well on this build, I should be able to make a pair of these, which seems appropriate since they're fairly short.

This was an older iteration of the design that's been tweaked a little (mostly the pommel length). The pommel and the light grey piece at the front will have etchings in a similar style to my Satele saber, though I haven't finished the design yet. My plan for the emitter is to try anodizing it and dying it black/grey, but I haven't decided if I want to try that or not - I'll see how I'm doing for the SWW deadline. The large grey section in the middle will be charcoal leather. I have a full hide from another project that ended up not using it (fwiw, it's the photo backdrop for most of my Satele shots :) ).
http://farm9.staticflickr.com/8245/8620549344_bf58fe210b.jpg (http://www.flickr.com/photos/26676500@N00/8620549344/)

I've made reasonable progress, though I haven't been nearly as good about documenting the process this time as I was last time. I just started polishing the pieces to remove the milling marks, but I think all of the pieces are cut. I'm undecided if I want to bevel the emitter like the sketch above, or leave the hard edge.
http://farm9.staticflickr.com/8128/8698976179_152c7442cd.jpg (http://www.flickr.com/photos/26676500@N00/8698976179/)

Kyaryo Ysoyav
05-01-2013, 02:12 PM
Looks great! Personally, I would bevel it. I like how emitters look with a softer edge, sort of flowing into the blade.

rogue9607
05-01-2013, 02:58 PM
Looks great! Personally, I would bevel it. I like how emitters look with a softer edge, sort of flowing into the blade.

Thanks! That's the way I'm leaning, though I think I'll get the cutout, etching, and leather grip done before making a decision on it.

cannibal869
05-03-2013, 10:40 PM
really liking the design so far. Good luck with the beveling! Just a note though - beveling an angled cut like that I think might require CNC? I don't think you can easily do that on a lathe, but I could be completely wrong...

rogue9607
05-04-2013, 01:56 AM
really liking the design so far. Good luck with the beveling! Just a note though - beveling an angled cut like that I think might require CNC? I don't think you can easily do that on a lathe, but I could be completely wrong...

You're right, it wouldn't be doable on a lathe. If I did the bevel it would be all hand work - and a lot of work at that.

I've had the saber tacked together while I work on a template for the leather grip, and I've been considering a design change. The front section gives me a nice surface for artwork/etching without the cut out. I'll finish the grip, then work on the etch design, and I think that'll naturally help me decide on the cut out and beveling.

hedgehog1
05-04-2013, 09:30 AM
Your 'Scrap' saber looks better than many of my 'non-scrap' saber designs.

I really do think you have a unique talent for this kind of work. :D

rogue9607
05-08-2013, 06:27 PM
Thank you Hedgehog!

I haven't had a chance to work on this the past week until today. I made the template for the leather grip, cut the leather, sewed it into a tube, and put everything back in place. I'm really excited how it's shaping up!

http://i1071.photobucket.com/albums/u515/rogue9607/Costuming%20and%20Props/Scrap%20Saber/IMG_20130508_201841-1.jpg (http://s1071.photobucket.com/user/rogue9607/media/Costuming%20and%20Props/Scrap%20Saber/IMG_20130508_201841-1.jpg.html)
http://i1071.photobucket.com/albums/u515/rogue9607/Costuming%20and%20Props/Scrap%20Saber/IMG_20130508_204647.jpg (http://s1071.photobucket.com/user/rogue9607/media/Costuming%20and%20Props/Scrap%20Saber/IMG_20130508_204647.jpg.html)
http://i1071.photobucket.com/albums/u515/rogue9607/Costuming%20and%20Props/Scrap%20Saber/IMG_20130508_204700.jpg (http://s1071.photobucket.com/user/rogue9607/media/Costuming%20and%20Props/Scrap%20Saber/IMG_20130508_204700.jpg.html)
http://i1071.photobucket.com/albums/u515/rogue9607/Costuming%20and%20Props/Scrap%20Saber/IMG_20130508_204714.jpg (http://s1071.photobucket.com/user/rogue9607/media/Costuming%20and%20Props/Scrap%20Saber/IMG_20130508_204714.jpg.html)

amwolf
05-08-2013, 06:35 PM
Sweet leather work... and a beautiful looking hilt. Extrapolating those angle cuts out onto a 2d surface still baffles me, so there is envy going on across a variety of elements.

rogue9607
05-08-2013, 08:38 PM
Thanks you. The template was actually easier than I expected. I had the hilt pieces together and traced the angles onto the main tube with a sharpie. I then wrapped the tube several times with clear packing tape, and cut it along those lines with an x-acto knife. I flattened the tape template onto a piece of paper, scanned that to my pc, and then traced the edges in Illustrator to give me a template. I printed the template on card stock, cut it out, and then used that template to cut the leather. The lines on the edge of the template were my 3/8" seam allowance for the sewing machine.

Having written that all out, it doesn't sound very easy, but I felt pretty simple as I was doing it.

The Yin
05-09-2013, 08:56 AM
^^ That's how it's done.
It sounds like a lot when read. But, though an exception to the rule, it's actually easier DONE then SAID. : )

rogue9607
05-18-2013, 01:35 PM
I haven't made as much progress as I'd hoped, but it is progressing. I wanted to have the static hilt complete including etching, switch, and recharge port before SWW, so that all I'd have left was the electronics. Work/life got in the way, and it didn't help that I can't find my graphics tablet. I managed to get all of the pieces sanded, polished, drilled, and tapped so that I could assemble the hilt for the parade.

http://i1071.photobucket.com/albums/u515/rogue9607/Costuming%20and%20Props/Scrap%20Saber/IMG_20130517_154233.jpg (http://s1071.photobucket.com/user/rogue9607/media/Costuming%20and%20Props/Scrap%20Saber/IMG_20130517_154233.jpg.html)

My plan is to finish it during the weeks between parades so that it's done by the end of SWW, if not sooner.

Next step: find the tablet so I can do the etching artwork!

rogue9607
05-21-2013, 02:00 PM
I finally found my tablet this week and was able to make some progress on the artwork. After one scrapped effort, I think I have something I'm happy with.

http://farm3.staticflickr.com/2818/8774757640_920545ebd3.jpg (http://www.flickr.com/photos/26676500@N00/8774757640/)

I should be able to get that printed tomorrow and hopefully transferred tomorrow night. If I have time tonight I'll try to bevel the emitter end and work on the plate for the switch/recharge port.

amwolf
05-21-2013, 05:01 PM
Sweet... this just keeps getting better. I really like a asymmetry in the artwork. Any plans on etching the pommel? It might start to get a little much, though...

Forgetful Jedi Knight
05-21-2013, 05:28 PM
It's coming along real well. Keep up the good work!

rogue9607
05-21-2013, 05:41 PM
I'm trying to decide on the pommel. My original plan was to put some kind of band around it (either similar artwork, something in aurebesh, etc). Now I'm uncertain if I want to continue the etching or have the pommel match the polish of the other side of the grip... kinda hard to explain. My current plan is to etch the top section and then see how it feels. There are several other places I'm considering etching (the emitter inside the cut outs, pommel, and the ring above the grip), but I'll just go one at a time and stop when it feels right. My fear is exactly what you said... it could get a bit much.

I got one of the switch plates done and a good part of the second done. Not sure if I've mentioned it, but I plan to have two of these and I've been making matching parts for the most part as I go, though the second set hasn't had any sanding/polishing/drilling yet. The large hole will be for the recharge port and the small hole is for the power switch.

http://farm8.staticflickr.com/7381/8777712814_525155e5f3.jpg (http://www.flickr.com/photos/26676500@N00/8777712814/)

Forgetful Jedi Knight
05-21-2013, 06:06 PM
I think an oval band like the one near the switch you showed would be good. I personally think etching down there would be overkill.

rogue9607
05-22-2013, 08:06 AM
I agree that etching down there would be overkill, which is why I'm only doing the upper section to start.

Made a bit more progress last night on the blade holder. I beveled the edge with a combination of a belt sander, file, and sandpaper.

http://farm4.staticflickr.com/3671/8786127044_90a2f86d90.jpg (http://www.flickr.com/photos/26676500@N00/8786127044/)
http://farm4.staticflickr.com/3675/8779559371_4e3e8b1e8b.jpg (http://www.flickr.com/photos/26676500@N00/8779559371/)
http://farm8.staticflickr.com/7286/8779563927_4497f5c626.jpg (http://www.flickr.com/photos/26676500@N00/8779563927/)

rogue9607
05-23-2013, 11:47 AM
I managed to get the etching done last night, though it didn't quite go as planned. I had a leak in my tape that was letting etchant slowly enter the tube. It didn't affect the pattern, but I didn't want to risk further failure and pulled the piece earlier than I'd expected to. The only downside of it is that the etch wasn't quite as deep as intended. I also cut out one of the slots. Here's a quick preview of me holding it together. I still need to cut the other side.

http://farm3.staticflickr.com/2880/8794571265_9dc634b592.jpg (http://www.flickr.com/photos/26676500@N00/8794571265/)

rogue9607
05-23-2013, 06:10 PM
I made good progress tonight. I cut the other side and I'm really happy with how the "shield" area looks. I polished up and cleaned all of the pieces, made a pvc sled for the eventual electronics, drilled all appropriate holes for the switch and recharge port, and made the visible part of the switch. Everything is now assembled, and the hilt is pretty much done... or at least done until after this week's parades. I don't have any electronics in this yet, but I may get a chance to work on that next week. Also, the activation switch should sit a little lower once I have the electronics in.

All in all, I happy with how it came out considering it was designed to make use of my scrap aluminum. The only part that's bugging me a bit are the proportions. Before the front was etched, the front seemed to have more visual weight and it looked balanced. Now the front seems tiny and visually out of balance. There are a couple of things I could still do like anodize the blade holder and dying it charcoal or black, or adding some etching to the pommel. I'm in no rush and will keep it as is for now and see if my opinion changes.

http://farm9.staticflickr.com/8269/8798023459_29d3422aa2.jpg (http://www.flickr.com/photos/26676500@N00/8798023459/)
http://farm6.staticflickr.com/5465/8798025777_cbd4a84ea5.jpg (http://www.flickr.com/photos/26676500@N00/8798025777/)
http://farm9.staticflickr.com/8545/8798028191_b3ddb11d41.jpg (http://www.flickr.com/photos/26676500@N00/8798028191/)
http://farm3.staticflickr.com/2817/8798030629_e18a6b88c5.jpg (http://www.flickr.com/photos/26676500@N00/8798030629/)

Silver Serpent
05-23-2013, 07:39 PM
You are getting really good at etching. It adds such a tremendous level of depth and detail, especially when done as well as you are doing. Keep up the good work!

JediRebel
05-24-2013, 05:35 AM
I wasn't too sure when I first saw you start this thread what the goal was. But let me say you far surpassed my expectation of what it could become! Much like your Satele saber, this has inspired me to make sure that etching is a part of my next project. Thank you for sharing your excellent art skills, sir!

amwolf
05-24-2013, 05:55 AM
Looks great! If you're hesitant about the visual balance, put it away for a few days if possible - don't look at it or think about it and work on something else. Come back with fresh eyes and see what you think.

rogue9607
05-24-2013, 07:40 AM
I honestly didn't know what to expect either, and it has mostly been a practice exercise so that I have experience with the lathe, more with etching, and working leather into the mix. I have some other projects that I want to move on to, so I didn't want to spend a huge amount of time on this one, but I also wanted that experience before tackling them.

Good advice about putting it away. I'll try to do that, but I don't think I'll fully be able to until at least next week, and even then I may start work on another saber so it will not be fully out of mind.

Batosai
05-24-2013, 10:57 AM
your echting is just amazing!!!
I love this saber

captain_mills
05-24-2013, 12:50 PM
Okay... stupid question... How do you cut out the etching pattern? Is it done by hand (crazy!) or do you have a program and machine that cuts it out for you?

By the way, holy cow this is cool!!

Silver Serpent
05-24-2013, 01:21 PM
Laser printer and special toner transfer paper. Wrap it around the metal piece, bake, and remove the paper. Voila! You have a perfect* toner resist applied to your parts.

*note* some touch-up may be necessary.

Denz
05-24-2013, 02:28 PM
The shroud and etching really makes this saber!

Honestly when I saw the earlier concept and pictures I was thinking things look a tad bland but now I take that all back.

Hats off!

rogue9607
05-25-2013, 09:12 AM
Laser printer and special toner transfer paper. Wrap it around the metal piece, bake, and remove the paper. Voila! You have a perfect* toner resist applied to your parts.

*note* some touch-up may be necessary.

Exactly it... though my experience so far for the note would be "significant touch-up will be necessary". Thankfully, the solid areas seem to need more touch up than the detail and are much easier to correct. I have some pictures of the transfer/touch-up process in my Satele thread, and this one was pretty similar.

I felt the same way about it being bland... especially as I'm standing next to my wife with her saber! I would've been rather ashamed to show mine next to hers if I didn't didn't also explain that mine was a work in progress and that I had a good vision for it.

So I lied... it turns out I wasn't done for the week. I don't have time to anodize/dye this weekend, but I figured I'd use spay paint to simulate the effect just to see if that helped with the visual balance, to see if I even liked it, and to help decide on a color. I shot one side of the blade holder with flat black, and the other side with gold (I didn't have copper on hand). I really like the black so far, but am interested to hear other opinions. I really think it helps with the balance, though the pommel still needs something...

http://farm4.staticflickr.com/3681/8816261123_8abc4959d0.jpg (http://www.flickr.com/photos/26676500@N00/8816261123/)
http://farm8.staticflickr.com/7439/8826847528_77f412f6fe.jpg (http://www.flickr.com/photos/26676500@N00/8826847528/)

amwolf
05-25-2013, 01:44 PM
I didn't think I'd like the black, but I do. Maybe keep the front slope bare metal to provide the same visual termination and accenting the grip gets... And yep, now the pommel needs something IMO - draw some cues from the front shroud and etch away. I say that as if it was the easiest thing in the world to do...

Or just don't stand near your wife when she's got her saber. This is the simpler course of action.

rogue9607
05-31-2013, 01:23 PM
I doubt that avoiding my wife's saber would turn out well... though I agree it is simpler. :) I did get one person who said she liked my saber better than my wife's... though she followed that up with the reasoning that it was more feminine.

I've been a bit slow with updates, but mostly because there isn't much new to really comment on. I've been working with the pieces for the second saber and think I have those ready to etch. I'm still undecided on the blade holder color and etch for the pommel, but I figured I'd sort that out after I had the second saber assembled. I'm still leaning towards black, though I did realize that I hadn't posted a pic of it in copper. The only copper I found in the garage had a "hammered" finish, which doesn't really help, but at least it gives a decent representation.

http://farm8.staticflickr.com/7426/8830673562_fedfb16ca1.jpg (http://www.flickr.com/photos/26676500@N00/8830673562/)

I'm also thinking of making a connector section to turn this into a staff, assuming that my time doesn't get pulled in other directions.

Skinnerman02
05-31-2013, 02:12 PM
For what it's worth, I like the hammered copper best. At least, in the image you posted. Seeing it in real life may show different results. Here, however, it presents enough of a contrast to make the hilt more visually appealing. The Gold was too light in tone and the black, to me, looked redundant. The copper offsets the rest of the colors and the hammered look gives the emitter an interesting, unexpected texture to the sleek design. Just my two cents.

amwolf
05-31-2013, 03:56 PM
I agree with Skinnerman.

KnightMoritz
06-24-2013, 05:58 PM
Whoa, that etching is really awesome! Really nice saber.

I'd make another one, similar to this, but weathered, like some sort of very old relic.

Crystal Chambers
06-25-2013, 06:27 PM
Copper for sure. Looking at the etch pattern I wouldn't think I'd like it but it looks much better after the process. You say etchant so I'm guessing this is not salt water etching. How did you etch it? While I agree the pommel needs something I wouldn't do too much and would consider matching to the blade holder colour or minimal etching like some stripes or something of the sort.

KnightMoritz
06-26-2013, 07:41 AM
For that kind of saber, in my humble opinion, black one makes it's design clean and elegant.

jedimastergarcia87
06-26-2013, 10:08 AM
Nice hilt. I really like the final designs. I more like the black myself. The copper does make the hilt more feminine. Also the hilt looks like from OR era.

rogue9607
07-20-2013, 03:20 PM
Thank you for all the opinions. I keep changing my mind on this, but I keep coming back to the black though that could change once I do some kind of hilt etching. The spray paint is holding up reasonably well for the moment, and I'll probably stick with it until both sabers are complete and then try to do something more permanent. Life has prevented too much saber work lately, but the good news is that I'm back at it working on a couple of projects for Dragon*con. The bad news is that these two sabers are lower on the priority list. Best case is that I'll have both finished and functioning, but that may be overly ambitious. My top priority is a more accurate Satele saber. I'll be starting a build thread on that one shortly.

e13azar
08-26-2013, 03:13 PM
I love it. Really like the etched look. Do you make any to sell?

rogue9607
08-28-2013, 05:50 PM
"Fred Baby" is alive! I now have a custom saber for myself that lights up. There's no sound, but that was the intent. The switch in the pommel is a bit odd, I know, but I wanted to be able to change led colors without opening the hilt or any crazy electronics, and this was fast/easy.

The top middle and right compare to the MR Mace Windu that I've been using on troops.

http://farm4.staticflickr.com/3701/9618852136_4b5241b71a.jpg (http://www.flickr.com/photos/26676500@N00/9618852136/)

Twigz
09-25-2013, 09:06 PM
I love the leather and bevel work. The subtlety and flow of it all looks great with the emitter! Quick question: could you possibly point me in the direction of good toner transfer paper (I can only find ads talking specifically about etching PCBs)? In the future I was going to try and etch a wood grain pattern into some shroud work, which I know I can't personally stencil with an exacto knife. xD>

rogue9607
09-26-2013, 03:03 AM
Thanks! I used PnP-Blue, which is intended for PCB etching. The transfer isn't perfect, but it's easy enough to touch up. I tried glossy magazine paper, but could never get satisfactory results.

Twigz
09-26-2013, 05:24 PM
I'll look into it, thank you!