Been a while since I've been here

[Nineteen]

So I decided I want to redo the lightsaber I made a few years ago before the new movie comes out. I have experience in building, but a lot of things have changed, so some clarity of some subjects would be welcome. First, my hardware list:
-1.5" sink tube
-End cap
-Blade safety plug/blade
-Recharge port kill plug
-Covertech belt clip
-1.5" to MHS adapter
-MHSV1 Blade Holder Style 25

My first question is on the blade holder. Is it possible to order custom lathe work to sort of reshape the blade holder so it's the same OD as the MHS adapter? I'd like to customize the end of the tube, and then put the blade holder inside it for a sort of stylized look, like so: http://puu.sh/bg1xu.png

Now the wiring, and of course, this is where it gets sticky. I'd like to use the Nano Biscotte, so let's use that as a base to work from.
-Nano Biscotte sound board
-NB Wiring Harness: http://www.thecustomsabershop.com/NB-V2-MWS-Header-and-Wiring-Harness-P961.aspx
-Speaker and female JST connector for speaker
-Rebel Star LED and MHS heatsink module: http://www.thecustomsabershop.com/Rebel-Star-LED-MHS-Heatsink-Module-P653.aspx
-Li-ion battery with JST connector: http://www.thecustomsabershop.com/Li-Ion-18650-37V-2600mAh-PCB-Protected-Rechargeable-Battery-Module-P672.aspx
-MWS recharge port: http://www.thecustomsabershop.com/MWS-Recharge-Port-P877.aspx
-Li-ion charger

Okay, time for the fun questions.
1. For the wiring harness for the Nano Biscotte board, what are all the connectors for? Going from top to bottom, numbered 1 to 4 and the "hanging" wire. Obviously 4 is the speaker, but what about the others?
2. Could there possibly be a diagram for the wiring I want? I think it's clear the kind of setup I want, and believe it's pretty standard. I'm not sure what I should plug into what.
3. I didn't include a switch because I'm not sure what I need. I like the look of anti vandal switches, but I'm not sure how to mount them, or if it's even possible to mount them, on a sink tube.
4. Any resistors needed? Any parts I'm missing?

I apologize if any of these questions have been answered many times before. I tried to find resources on how the modular wiring system works, but couldn't find any.

[Forgetful Jedi Knight]

See my replies in yellow:


So I decided I want to redo the lightsaber I made a few years ago before the new movie comes out. I have experience in building, but a lot of things have changed, so some clarity of some subjects would be welcome. First, my hardware list:
-1.5" sink tube
-End cap
-Blade safety plug/blade
-Recharge port kill plug
-Covertech belt clip
-1.5" to MHS adapter
-MHSV1 Blade Holder Style 25

My first question is on the blade holder. Is it possible to order custom lathe work to sort of reshape the blade holder so it's the same OD as the MHS adapter? I'd like to customize the end of the tube, and then put the blade holder inside it for a sort of stylized look, like so: http://puu.sh/bg1xu.png

You would need to talk to Tim.

Now the wiring, and of course, this is where it gets sticky. I'd like to use the Nano Biscotte, so let's use that as a base to work from.
-Nano Biscotte sound board
-NB Wiring Harness: http://www.thecustomsabershop.com/NB-V2-MWS-Header-and-Wiring-Harness-P961.aspx
-Speaker and female JST connector for speaker
-Rebel Star LED and MHS heatsink module: http://www.thecustomsabershop.com/Rebel-Star-LED-MHS-Heatsink-Module-P653.aspx
-Li-ion battery with JST connector: http://www.thecustomsabershop.com/Li-Ion-18650-37V-2600mAh-PCB-Protected-Rechargeable-Battery-Module-P672.aspx
-MWS recharge port: http://www.thecustomsabershop.com/MWS-Recharge-Port-P877.aspx
-Li-ion charger

Okay, time for the fun questions.
1. For the wiring harness for the Nano Biscotte board, what are all the connectors for? Going from top to bottom, numbered 1 to 4 and the "hanging" wire. Obviously 4 is the speaker, but what about the others?

It's in the manual (located in the description in the store)

2. Could there possibly be a diagram for the wiring I want? I think it's clear the kind of setup I want, and believe it's pretty standard. I'm not sure what I should plug into what.

Yes, there is a section for the board and I posted diagrams there. Look in Saber Sound, you'll find them there if you look around.

3. I didn't include a switch because I'm not sure what I need. I like the look of anti vandal switches, but I'm not sure how to mount them, or if it's even possible to mount them, on a sink tube.

You need a momentary switch of some type. The rest is up to you.

4. Any resistors needed? Any parts I'm missing?

You will likely need a resistor the the main LED, and for the LED int he resistor if you go that route.

I apologize if any of these questions have been answered many times before. I tried to find resources on how the modular wiring system works, but couldn't find any.

[Nineteen]

What I mean with the switch is, how do I actually mount the thing on the tube? The last time I made a lightsaber, it was hard to actually get in the tube and hold nuts in place while I put in screws. I can't imagine trying to screw in a nut on the inside.

[Forgetful Jedi Knight]

If you're using a sink tube, that's what you would need to do.

[Nineteen]

I can't find the explanation of what the NB wiring harness pieces are. I'm talking about this: http://www.thecustomsabershop.com/NB-V2-MWS-Header-and-Wiring-Harness-P961.aspx

The description of those connections are not in the NB manual, and I can't tell where some of the wires go in the picture.

[Forgetful Jedi Knight]

The description of what those connections go to are in the boards description in the store AND on PAGE 6 of the manual. You amy want to re-read the manual again.

[Nineteen]

This is Page 6. http://puu.sh/bgfM1.jpg

That does not describe this: http://puu.sh/bgfNu.jpg

What are the four plugs and the hanging wire? I can't tell from the picture where all of the wires go.

[Forgetful Jedi Knight]

This is Page 6. http://puu.sh/bgfM1.jpg

That does not describe this: http://puu.sh/bgfNu.jpg

What are the four plugs and the hanging wire? I can't tell from the picture where all of the wires go.

Uh yeah, they do, if you start from the top (Red and white wire), they tell you what is what. I'll give you a hand, the hanging wire is the FoC wire. I got that because I read what I gave you to read. ;) One is a battery, one is a switch, one is a LED and one is a speaker.

[Nineteen]

Uh yeah, they do, if you start from the top (Red and white wire), they tell you what is what. I'll give you a hand, the hanging wire is the FoC wire. I got that because I read what I gave you to read. ;) One is a battery, one is a switch, one is a LED and one is a speaker.
Okay, so red/black connects to the battery pack, white/blue would connect to the LED module, yellow/yellow would connect to the switch somehow (how would THAT work?), and green/green is the speaker, like I said before.

Maybe I should just give up on using the Modular Wiring System. I somehow can't make the translation between wiring diagrams and the MWS connectors I'm seeing. I understand how your wiring diagram works, but I don't understand how to use MWS to achieve it.

[Forgetful Jedi Knight]

It works a lot easier if you have everything in front of you. ;) You figured them out.

[Nineteen]

I just need to know if I'm going to have to make any cuts, or if the MWS will be enough. I'm not doing anything more than your diagram with the kill switch, so is everything on my list okay? Will I have to get a couple connectors for the switch (one for the LED, one for the switch itself)?

[Forgetful Jedi Knight]

The switch does come with JST connectors for both, but you would need to do the wiring for the LED portion of the switch yourself. (to the 3.3V pad and the battery (-))

[Nineteen]

Switches come with two JST connectors?

[Forgetful Jedi Knight]

Switches come with two JST connectors?

http://www.thecustomsabershop.com/MWS-Short-Momentary-16mm-AV-Switch-Nickel-P878.aspx

[Nineteen]

Okay, so you're talking about wiring the LED on the switch like this: http://puu.sh/bjciH.jpg

So I'd have to buy a JST connector and a resistor, then connect that like in the diagram? Then connect the JST connector to the switch's JST connector?

[Silver Serpent]

Well, the MWS switch with two JST connectors already has the DynaOhm resistor in place. You won't need another resistor. The rest is correct though.

[Nineteen]

Do you guys have any suggestions for batteries? I was going to go with this (http://www.thecustomsabershop.com/Li-Ion-18650-37V-2600mAh-PCB-Protected-Rechargeable-Battery-Module-P672.aspx). What kind of run time can I expect with that cell? Would it be better to go with this (http://www.thecustomsabershop.com/4AAA-Battery-Holder-with-JST-connector-P724.aspx) and four of these (http://www.thecustomsabershop.com/AAA-1000mAh-NiMH-Rechargeable-battery-P475.aspx)? Is there any difference between run time and wiring that I need to be concerned about?

Oh, also, will I need anything like a BuckPuck?

[Forgetful Jedi Knight]

The 18650 will give you a much better run time than the other options. No you don't use a buck puck with the NB sound cards.

[Nineteen]

Okay, here's my new shopping list. This time I want to make sure everything is compatible in regards to JST connectors and such:

-1.5" sink tube
-Sink tube end cap
-MHS blade holder
-2" double female threaded connector
-.75" male/female extension
-Safety plug
-Covertech belt clip

-LED Module: http://www.thecustomsabershop.com/Rebel-Star-LED-MHS-Heatsink-Module-P653.aspx
-Nano Biscotte sound board with MWS Header and wiring harness: http://www.thecustomsabershop.com/NB-V2-MWS-Header-and-Wiring-Harness-P961.aspx
-Charge port (kill switch) with kill plug: http://www.thecustomsabershop.com/MWS-Recharge-Port-P877.aspx
-Battery: http://www.thecustomsabershop.com/Li-Ion-18650-37V-2600mAh-PCB-Protected-Rechargeable-Battery-Module-P672.aspx
-Charger: http://www.thecustomsabershop.com/37V-Li-ion-smart-charger-with-21mm-plug-P890.aspx
-Speaker
-Switch: http://www.thecustomsabershop.com/MWS-Short-Momentary-16mm-AV-Switch-Nickel-P878.aspx
-Two female JST connectors. One to wire to the speaker to connect to the sound board wiring harness and one to wire to the sound board for the switch LED.

Note: The MHS hardware stuff is for a chassis anchor. The blade holder will go in one end of the female connector. This is for the LED module. The male/female extention will go on the other end, and this will have one of the chassis discs.

Question: I am unsure how mounting the switch will work now. I think the way I have it set up will work, but the switch is still the big kicker. I want it around the middle of the saber, so I don't know how that will work concerning a chassis.

[Forgetful Jedi Knight]

Any mockup picture(s) of the hilt in question?

[Nineteen]

It's going to look very much like this one. I'm pretty much only redesigning the insides and making some upgrades (Hasbro to NB and cleaning up some screw placements/dremel cuts). And obviously the anti-vandal switch. The switch, recharge port, and clip placements I want to keep the same. The inside order would ideally be: LED, crystal chamber thing if I have room for it, sound module (sound board protected by a small piece of PVC), battery, speaker, all mounted on a chassis. I might be able to mount the sound module and battery side by side, but I'd have to have everything in front of me to see if it would fit.

http://puu.sh/bg57h.JPG
http://puu.sh/bg566.JPG
http://puu.sh/bg56G.JPG
http://puu.sh/bg57I.JPG