Hilt build questions (general, activation box 8, tactile switch, accent LED)

[Rich330]

I'm working on drafting another design and I have a few questions which I have not been anble to answer with the "Search" button.

It's a purely MHS build, based roughly on Luke's ROTJ saber(s). This is the basic construction before switches/activation boxes/the jack socket.

http://i7.photobucket.com/albums/y261/Rick_N_Backer/Lightsabers/LS-3302V01Basicnoboxes_zps1c5ae5c0.jpg

Pommel style 3 v2
4" double female plain extension
Ribbed / Choke Combo (with powder coating RC04)
Blade holder style 5

I would very much like to use activation box style 8 but there's a couple of things I don't understand.

Would it be possible to mount it flush with the front edge of the plain 4" section as shown here?
http://i7.photobucket.com/albums/y261/Rick_N_Backer/Lightsabers/LS-3302V01Graflexbox7or8_zpse19615ee.jpg

How exactly is it generally fastened to the hilt? I would have imagined that it would be screwed in place like box no. 1. I guess I'm also looking for the appropriate mounting holes service in the online shop too.

OK, so let's assume my box can be positioned as above ... Would the following be possible?
I would like to have a tactile momentary switch installed on the back vertical panel (nearest the pommel end) to switch on the saber.
I would also like an accent LED inside the box (I believe the PCB card is quite transluscent). Would I be able to have it mounted in the base of the box and are there other/better solutions?
http://i7.photobucket.com/albums/y261/Rick_N_Backer/Lightsabers/LS3302Boxideas_zpsb182fc96.jpg (http://s7.photobucket.com/user/Rick_N_Backer/media/Lightsabers/LS3302Boxideas_zpsb182fc96.jpg.html)

Thanks in advance for your help.

[amwolf]

Yes, that's possible, but remember that roughly 5/8" of the MHS end will contain threads, so you're best off avoiding that area. I've used (not on the same build) button head screws, a recharge port, and JB Weld to hold that box in place. You can drill mounting holes inside the box, but you run out of room faster than you think... As for the switch I've mounted that switch out the side of the box but the radiused inner corners may make it problematic to go out the back. If you're asking Tim to drill the hole, ask him if it will work; otherwise you can get creative with spacers or a dremel but then that work is all on you. You'll need to drill a hole through the MHS to get your wiring up into the box, too. As for the accent LED, I'd switch to a 5mm loose LED and just lay it in the box - easier install IMO.

[Rich330]

Yes, that's possible, but remember that roughly 5/8" of the MHS end will contain threads, so you're best off avoiding that area. I've used (not on the same build) button head screws, a recharge port, and JB Weld to hold that box in place. You can drill mounting holes inside the box, but you run out of room faster than you think... As for the switch I've mounted that switch out the side of the box but the radiused inner corners may make it problematic to go out the back. If you're asking Tim to drill the hole, ask him if it will work; otherwise you can get creative with spacers or a dremel but then that work is all on you. You'll need to drill a hole through the MHS to get your wiring up into the box, too. As for the accent LED, I'd switch to a 5mm loose LED and just lay it in the box - easier install IMO.

Thank you. That's all very useful.

I might go back to the drawing board on this and consider using activation box style 1 in the middle of that section. As much as anything I just want a more old-fashioned squared box style instead of the more modern looking, sleek, rounded boxes. Box style 1 achieves the look I want just as much as style 8.

How about this? Does this look like a more practical design?

http://i7.photobucket.com/albums/y261/Rick_N_Backer/Lightsabers/LS-3302Box1nothreads_zps476a1a1a.jpg (http://s7.photobucket.com/user/Rick_N_Backer/media/Lightsabers/LS-3302Box1nothreads_zps476a1a1a.jpg.html)

http://i7.photobucket.com/albums/y261/Rick_N_Backer/Lightsabers/LS-3302Box1boxandrechargeport_zpsa49c5237.jpg (http://s7.photobucket.com/user/Rick_N_Backer/media/Lightsabers/LS-3302Box1boxandrechargeport_zpsa49c5237.jpg.html)

http://i7.photobucket.com/albums/y261/Rick_N_Backer/Lightsabers/LS-3302Box1tactileswitchhole_zpsab3e2f98.jpg (http://s7.photobucket.com/user/Rick_N_Backer/media/Lightsabers/LS-3302Box1tactileswitchhole_zpsab3e2f98.jpg.html)

http://i7.photobucket.com/albums/y261/Rick_N_Backer/Lightsabers/LS-3302Box1PCBandaccent_zps7c61be59.jpg (http://s7.photobucket.com/user/Rick_N_Backer/media/Lightsabers/LS-3302Box1PCBandaccent_zps7c61be59.jpg.html)

Would I have any problems getting the momentary tactile switch and the LED wired and in the box?