PDA

View Full Version : Jay-gon's Chrome Saber 41 (CS-41)



Jay-gon Jinn
03-27-2015, 09:39 AM
I have an acquaintance in the Rebel Legion Base I'm part of that needs a new lightsaber. He had one that worked well for getting membership, but once we were costuming together at the Grand Rapids Griffins Star Wars Night back in February, and seeing my personal sabers and the ones I recently upgraded for the other members of the club, it became apparent to him that he needed something....different. Since I had finished most of the upgrades for our other members, I offered to see what I could do for him and suggested looking through my site and see if any of the previous builds interested him, and he chose my re-worked Chrome Saber 2 design:

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/100_3562.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/100_3563.jpg

As with that saber, this one will be built on a budget, but hopefully will still look good and most importantly, function as a good trooping saber.

So, here's the basic parts for the hilt:

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/IMAG0419.jpg

These are the RICE (Real-Time Internal Configuration Editor) and recharge ports....I was thinking about putting these in the pommel, but that will depend on a couple of things that will be worked out between Zark and myself:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/IMAG0423.jpg

This is the led housing/heatsink assembly:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/IMAG0422.jpg

These pieces will make up the front and center sections of the hilt....these started out as a 4" MHS extension that I had Tim at The Custom Saber Shop(TCSS) machine some grooves into to make it easier to part it up into the pieces you see here:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/IMAG0421.jpg
The threaded ends will allow for attaching the blade holder and pommel, the un-threaded center section will house the main switch, and possibly the aux switch as well or the recharge port. The other piece shown there with the polywashers on it will serve as the front grip. The washers are on there as a place holder for now, and may be used on this, but I might have something else in mind for that part, too.

This last piece is the main piece. The chrome tube will serve as both the rear section of the hilt body and also will be used to make the emitter sleeve/shroud.
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/IMAG0420.jpg

Cutting and drilling has already commenced, and I will update this as work progresses.

Jay-gon Jinn
03-27-2015, 09:40 AM
his is what I managed to get done yesterday before going off to work at the real job. ;D

I started off by cutting the chrome tube down to size...I went with 5"on this piece. That should be enough to house everything that will go into this section, the pommel mount, speaker, battery and probably the RICE port on a pigtail since this one's battery pack will be removable:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3775.jpg

The un-threaded section of the MHS parts goes in one end:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3776.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3777.jpg
It has a nice flush fit with the end of the tube...I squared off the tube and the MHS piece on my disc sander...sorry no pics of that. :-\ This piece will be held to the chrome tube using a few 8-32 button head screws. The forward grip piece will fit inside this part and will have a nearly press-fit secured further by the aforementioned 8-32 button head screws.

The pommel mount fits in the other end of the chrome tube, obviously:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3778.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3779.jpg
This also has a nice, flush fit. This piece will also be secured to the chrome tube via 8-32 button heads screws, and also the CT button screw. I'll add those later, after I finish up the forward grip section.

Here's the rear grip section as it is right now:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3780.jpg
This part will likely get my tubing cutter grip marks in a pattern I have yet to determine...

For the forward grip section, I'll need to cut down the 1.25 x 1.15 aluminum tube. I'll use the tubing cutter for that, since it isn't that thick, and being as short as it is, would be nearly impossible to do on the mitre saw (no way to really secure it due to the design of the saw's table):
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3781.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3782.jpg

The tube will fit into the two MHS pieces seen here:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3783.jpg
This is basically how I make the Padawan Series sabers I also build, and they seem to hold up to some spirited dueling, so I know this one will be pretty sturdy as well.

These grip tube will slip into the MHS parts like this:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3784.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3785.jpg
The intent is to have to practically press-fit the parts, to maintain structural rigidity, and alignment so we don't end up with a bent saber. (I've done that before on a couple of others in the past for myself....oops.)

I'll have to hone the inside of the MHS parts for this work, since the I.D's of the pieces is identical to the tubing's O.D. of 1.25".
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3786.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3787.jpg
This is my 1.25" cylinder hone I got from McMaster-Carr.com. I attached it to my variable speed drill motor, and this won't take long, due to the low amount material I need to remove.

I fit the hone into the MHS part:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3788.jpg
I started with the emitter mount and because I didn't want to hone the threads, too, attached the emitter to act as a stop for the hone.

I put on my heavy-duty leather glove:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3789.jpg
Another option would be to put the part in a vise, but I was not going to run the drill very fast, so friction heat build up isn't a concern this time around.

After a few minutes of checking and honing, the parts fit:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3790.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3791.jpg

I did the same to un-threaded piece, and eventually it fit as well:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3792.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3793.jpg
cool...it's starting to look like a saber!

I happen to have a piece of chrome tubing I cut for something else and hadn't ended up using, but it seems a perfect fit for the cover on the blade mount:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3794.jpg

Now the real work begins....next post!

Jay-gon Jinn
03-27-2015, 09:40 AM
Okay, got some time the other day to do more work on this one. The next step in this one's build was to drill for the main activation switch, so I set up the drill press with a 3/8 bit (I like to start with a smaller hole, then step up to the 5/8"). Next, I marked off the hole location on the un-threaded MHS section:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3795.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3795.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3796.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3796.jpg)

After drilling with the 5/8" bit, the hole just needed a little be-burring:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3797.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3797.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3799.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3799.jpg)
I used a sanding drum on my Dremel for that..no pics, sorry.

Test fit the switch and the mounting bezel:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3798.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3798.jpg)

Now I had to decide if I wanted to try and drill a corresponding hole in the Chrome tube (which can be a pain to align properly if you don't drill both parts at once, or try something a little different:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3800.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3800.jpg)
If instead of a hole for the switch, I decided to make a slot to ease assembly of the saber later on.

I started by drilling a hole using the 5/8" bit that was still in the drill press:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3801.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3801.jpg)
This has to be done slowly, or you risk destroying or damaging the tube. This large of a bit has a lot of bite, and the chrome tube is very thin, making it easy to deform if you drill to quickly.

Using a reinforced cutting disk on the Dremel, I cut the section out between the hole and the end of the tube, following the lines I had drawn:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3802.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3802.jpg)

I then spent a few minutes with a sanding drum on my Dremel and cleaned up the cuts, removed the burrs, and enlarged the slot's radius around the switch. Once that was done, I hand sanded the edges with some 400 grit paper and checked the fit:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3803.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3803.jpg)

Now I'll need to drill and tap for the 8-32 screws that will secure the rear section to the switch mount:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3804.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3804.jpg)
I have three way to do this...either 2 screws on either side which would also secure the front grip section to the switch body, or three screws equally spaced around the diameter of the tube...or I could use 4 screws with two on either side of the saber....the front screws being used to secure the connection to the forward grip, the other two securing the rear grip and possibly the recharge port c-clip, which isn't really required. We'll see what Zark thinks, since it's his saber. ;D

Silver Serpent
03-27-2015, 10:24 AM
I've always loved your sabers. They're the perfect combination of hardware and MHS.

Are those polywashers going to stay white, or are you going to add color to them somehow?

Jay-gon Jinn
03-27-2015, 01:38 PM
I've tried painting them before, but paint just slides off of them, or flakes off after it dries, so of we decide keep them, they will remain white. The interesting thing I found when using them on one of my own, is they take on a pearlescent look when you polish the aluminium underneath, or install them over a chromed piece.

Silver Serpent
03-27-2015, 07:14 PM
I've heard you can dye some plastics with a combination of Rit dye, water, and a *little* bit of acetone. Don't leave it to soak, or the acetone will destroy the plastic. It might be worth looking into.

setelf3of5
03-27-2015, 08:44 PM
Jay-gon Jinn Very nice work, I have always liked your sabers... Great work!

Jay-gon Jinn
03-30-2015, 09:06 PM
I worked on this a bit before going to work Monday afternoon, here's what I got finished....

I had to mark the chrome tube for the mounting screws that will hold the saber together, and in order to ensure that they are drilled in the proper alignment to each other, I used my drafting circle template to mark the tube at 90 degree intervals, starting by finding the center of the slot I cut for the switch:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3805.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3805.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3806.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3806.jpg)
Using the drafting scale to draw the line (it is three sided, so it fits on the curve of the tube perfectly) I was able to line it up on the 1 1/2" hole in the template:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3807.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3807.jpg)

I marked it off all the way around:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3808.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3808.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3809.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3809.jpg)

I then measured and marked for the first of the four mounting screws I decided to go with, and drilled the hole in the chrome tube first:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3810.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3810.jpg)

I slid the switch body piece into place and then drilled and tapped the hole in that, too:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3812.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3812.jpg)

I did the same on the other side:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3813.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3813.jpg)

I measured, marked, drilled, and tapped for the other two screws, and installed the 4 screws:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3814.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3814.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3815.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3815.jpg)

I did the same for the MHS section that will house the speaker mount and also the pommel:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3816.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3816.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3817.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3817.jpg)
I went with just one on either side here, because to add two more to balance the appearance would mean drilling and tapping into the threads for the pommel and once the screws would be installed, it would be impossible to unscrew or screw in the pommel. One of these screws will be removed and replaced by the covertec button and it's screw.

It's starting to look like saber:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3818.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3818.jpg)

Next thing I worked on was the front grip tube:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3819.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3819.jpg)
I removed two front screws on either side and used the existing holes as guides for drilling and then tapping the forward grip section. I tapped the holes, re-istalled the screws, and checked for straightness using my drafting scale:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3820.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3820.jpg)
Looks pretty good! I spun it in my hand as well, and it looked straight and true to me.

I'll need to remove a bit of the grip tube to clear the switch:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3821.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3821.jpg)
That won't take much, I'll use the Dremel to do that.

I also need to shorten up the chrome sleeve for the top of the forward grip, since this was originally cut to work with a style 5, 8, or 16 blade holder and would extend just beyond the base ring on those:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3822.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3822.jpg)
I'll see if I can get to that tomorrow, along with the shroud for the emitter. I haven't decided how I'd like to mount that shroud, I think this has enough screws showing already....

Jay-gon Jinn
03-31-2015, 08:45 PM
A little more work on this....

I put the forward grip section in the drill press vise and used the cutting wheel on my Dremel to wedge out a section for clearing the switch:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3823.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3823.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3824.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3824.jpg)

Since I had it all apart again, and to prep the grip section for my alternative to the white washers, I put the parts on my adapter and gave them a spin on my drill with some sandpaper to clean up the parts and then re-assembled it (with the washers for now):
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3825.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3825.jpg)

I also cut down the chrome sleeve for the emitter mount on the forward grip:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3826.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3826.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3827.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3827.jpg)
It's nice and square with the MHS section, so that's almost done....i just need to drill and tap for two more screws, which will hopefully be the last ones I use on this.

Next up, cutting the emitter shroud in the Graflex s-curve:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3828.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3828.jpg)
Once that's done, I'll see what I can do to replace those washers with something...better....hopefully. (I do still need to keep this within Zark's budget ;) )

Star Bird
04-01-2015, 03:32 PM
Looks great can't wait to see it finished!

Jay-gon Jinn
04-09-2015, 08:51 PM
A small update on this build...

After drilling and tapping for the two screws that secure the blade mount to the aluminum grip tube, which for some reason turned out to be 10-32 threads (I don't know what I drill with that bit before putting this saber in the press) I went with those screws and finished up that bit of work.

I moved on to the emitter shroud after that:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3834.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3834.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3835.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3835.jpg)
I drew the S-curve on the chrome sleeve by hand, loaded it into the vise on the drill press then started by using the cutting disc on my Dremel to remove as much material as I could, then I switched to a 60 grit sanding drum and removed the rest:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3836.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3836.jpg)

I checked it for fit, and looks, and it looked good:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3837.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3837.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3838.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3838.jpg)

I deburred the edges and removed the remainder of the marks from the marker:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3839.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3839.jpg)

A shot of the whole saber with the emitter shroud sitting in place:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3840.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3840.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3841.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3841.jpg)

I looked at it for a bit trying to decide which way to go for mounting the sleeve to the emitter....I started out by drilling and tapping for the 10-32 blade thumbscrew, then added the two 8-32 screws on the sides for continuity's sake...it doesn't look that bad, I think:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3842.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3842.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3843.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3843.jpg)

Now it just needs some detailing on the rear grip section:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3844.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3844.jpg)

And something besides the white washers:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3845.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3845.jpg)
Working on that next....and then it will time to figure out what we're going to do for electronics, aside from the blade led (a triple Cree or Rebel) and sound board (Crystal shard 2.5) which we already have.

Jay-gon Jinn
04-13-2015, 09:59 AM
I worked on the alternative to the washers today!

I have a bunch of pieces of aluminum tubing that can slide over each other for layers on a saber, so I used a scrap piece of that for this:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3846.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3846.jpg)
This is a piece of 1.375" x 1.259" tubing...I marked off three locations for holes to be drilled and used a 1/4" drill bit to drill it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3847.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3847.jpg)
I went all the way through for each hole.
Next, I marked off some line with my tubing cutter, connecting each set of hole to the corresponding hole on the opposite side:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3848.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3848.jpg)

Then, using a reinforced cut-off wheel on my Dremel, I cut along the line on the first set of holes:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3849.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3849.jpg)

Then did the rest, and after some time with the files, I had this:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3850.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3850.jpg)
Now it's ready for some sanding and determining if I want to paint & bake it.

Star Bird
04-14-2015, 04:29 PM
that looks like its going to be epic

Jay-gon Jinn
04-15-2015, 09:08 PM
And here's what I got done before heading off to work Wednesday afternoon....

I put the grip section onto a scrap piece of aluminum tubing and sanded and sanded and sanded it some more, until I finally had this:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3851.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3851.jpg)
Now that's much better than the washers!

There are, however, some issues with it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3852.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3852.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3853.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3853.jpg)
There's a nice little nick in the rounded end of the first grip slot on this side of the saber. I can probably get rid of that with more filing, which will not hurt anything, since I was thinking this should be where the AUX button will go. Zark and I will have to discuss that next. also notice the scratches on the inner tube as well.

The other problem with the piece is on the other side:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3854.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3854.jpg)
This is what happens if you don't maintain tight control of your Dremel when cutting a piece of tubing...the disc got away from me and skittered across the tube, leaving these marks. I sanded the crap out of the part to lighten them up as best I could, and may still work on it some more, especially if I file the the grip slots deeper on the other side to eliminate that little gouge.

There's also a nice scratch in the inner grip tube on this side:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3855.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3855.jpg)
The problem with sanding out scratches on the inner tube is that the more material I remove, the more loosely the grip section fits. I had planned on it being a tight fit in between the two MHS sections and be pressed in between them enough not to allow for it to spin, but that didn't work out as planned. ::)

I could fix that by epoxying the two pieces together, or using the AUX button, depending on which type I use, to prevent it from moving. One way to hide the scratches would be to paint the grips and the inner tube, but I'm kind of liking the brushed aluminum look....it contrasts nicely with the chrome pieces without being a distraction.

Overall, though, I think this is a big improvement over the original design:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3856.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3856.jpg)

Lilac
04-24-2015, 07:46 PM
Awesome addition to the design!
I think a bit of brass would be neat.

Lilac

setelf3of5
04-24-2015, 08:10 PM
It looks very good, I have only finished one saber and found it hard not to have a few scratches.

Star Bird
04-24-2015, 11:35 PM
Dang ! That looks good who knew a sink tube saber could look THAT GOOD.

Jay-gon Jinn
05-06-2015, 08:38 PM
Dang ! That looks good who knew a sink tube saber could look THAT GOOD.
Um, me? LOL....

Couple of small updates on this one....

Zark opted for the small white mini-tactile, and I just happened to have a 3-D printed tactile switch mount from TCSS:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3859.jpg
Being designed for the MHSv1 i.d. of 1.25", it was of course, too big to fit. I cut a small section of it out to make it into a "C-clip" instead, like I usually do with the sink drain pvc pieces I use for the other push button mini switches:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3860.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3861.jpg
A little trimming, and it was a perfect fit.

I marked off on the hilt where the hole needed to go:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3862.jpg

Then drilled it, and checked the fit:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3863.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3864.jpg
Nice, I like that look, and it is perfectly functional. Small enough to not be a bother when handling the saber, yet easy to activate.

So here it stood after that bit of work last wek:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3865.jpg

I still had the small issue of the grip section wanting to spin, since it's a loose enough fit to do so, and to fix that and solve another issue I'll get into later, I decided to drill adn tap for a small 4-40 button head screw:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3866.jpg
Being small and out of the way, this will serve a dual purpose.

This is the pommel grille I plan to use, it's the last one I have:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3867.jpg
There are a couple of other options, one being the standard chrome grille I use on the Padawan Series sabers I build, or I could use one of the more expensive MHS MPS inserts.

Here's what I finished today:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3868%202.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3869.jpg
This is the sound board cradle, or the bare bones of it anyway. Made from a TCSS chassis disc for the ribbed extensions, 4-40 threaded rod, nylon spacers and 4-40 hex nuts in brass, this fits inside the 1.25" aluminum tube just fine, but it's a bit loose since the i.d. of the piece is 1.18" and the MHS ribbed's are 1.15".

Remember the 4-40 screw in the grip section? Here's the other purpose it will serve:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3870.jpg

I drilled and tapped the chassis disc with 4-40 threads right in the center of the disc:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3873.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3874.jpg
The screw threads right in...

Installed:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3875.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3876.jpg
The cradle has a nice solid fit to it, so if the saber should see any dueling, it will be securely held in place.

From the emitter end:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3877.jpg
This should allow for easy enough access to the sd card with the board mounted in the correct direction. It will require the use of tweezers or needle nosed pliers, but I will also be adding a RICE port pig tail to the saber which will be inside the battery compartment and hidden when not in use.

Speaking of the battery compartment:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3878.jpg
This is a low tech, but cheap way to keep the single 18650 from rattling around in side the hilt. Just a simple piece of foam wrapped up and fit in between the MHS pieces. I tried to use some chassis discs to mount the cell, but none of the parts I have on hand would allow for the cell to be easily removed and replaced. Replacement is necessary on this saber as it will be serving a s a trooping saber and will need to be in use for 4-5 hours at a time.

With all of that done, this saber is ready for final assembly! More on that as work progresses. ;D

Noyl Wendor
05-06-2015, 09:23 PM
Very nice. ;) I dig your work

Jay-gon Jinn
05-07-2015, 09:51 AM
Wiring commenced today! Here's what I managed to finish before stopping to get ready to go to the real job.

I started prepping the board by pre-tinning the pads, then added the wires:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3879.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3879.jpg)
I have my own color code I like to use for these Crystal Shard 2.5 installs:
Red (twisted): battery positive
Black (twisted): battery ground
Blue: RICE RXD
Purple: RICE TXD
Yellow: speaker (both positive and negative)
Gray: AUX button (negative has black tracers added)

Blade led wiring code
Orange: Common positive for the blade led
Red: red led ground
Green: green led ground
Blue: blue led ground

Switch wiring color code
White: switch positive
White/tracer: switch ground
Orange: Led positive
Brown: led ground

With the wiring on the board done, I moved on to installing the board which involved attaching the switch wiring:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3880.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3880.jpg)
This will be secured to the clear plastic mount I added (no pics of that) by foam mounting tape for cushioning, and then a "strap" of heat shrink tubing.

To get the battery connector, speaker and RICE port wires through the rear section, I tapped them up with masking tape:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3881.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3881.jpg)

Now I needed to add the AUX button:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3882.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3882.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3883.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3883.jpg)

With that soldered in place, I could assemble the front grip section:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3884.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3884.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3885.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3885.jpg)
Getting that screw and the hole in the chassis mount disc to line up was easier than I expected, and the screw threaded right in, securing the chassis.

Now I had to get the switch installed:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3886.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3886.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3887.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3887.jpg)

Installed:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3888.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3888.jpg)
There should still be plenty of room to reach in there and install the SD card. I was planning to do that before I put it together, but got ahead of myself.

Next up, is the pommel end of the saber, where I'll have to attach the speaker and RICE port:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3889.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3889.jpg)

Star Bird
05-11-2015, 07:07 PM
Nice.

Jay-gon Jinn
05-12-2015, 09:42 AM
I had time this morning to work on the speaker and RICE port wiring today:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3889_1.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3889_1.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3890.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3890.jpg)

I plugged in the battery and heard a boot sound, pressed the activation button, and it powered on:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3891.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3891.jpg)
I tested the RICE port before heat shrinking it to ensure it worked, and it did. The only thing left is to wire up the main blade led which arrived in the mail on Saturday morning. I hope to have this finished up tonight or tomorrow morning.

Jay-gon Jinn
05-19-2015, 09:10 PM
Okay, final update on this one, hopefully! ;D

After getting the correct resistors in the mail yesterday, I made time this morning to wire up the led. This involved removing the front grip section and adding in resistors for the red, green and blue Cree XPE 2's. Once those were inline, I soldered up the led:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3892.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3892.jpg)

Before buttoning it up, I thought now would be a good time to check it to make sure it actually works. I plugged the battery and hit the activation switch:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3893.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3893.jpg)

Then scrolled through the other colors by pressing both the Activation and aux switches at the same time:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3894.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3894.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3895.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3895.jpg)
Cool, all three colors lit up, and were pretty danged bright.

I added the adhesive pad to the back of the led. This not only helps with thermal transfer, but will also act as an electrical insulator for the led:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3896.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3896.jpg)

After some tedious moments peeling off the backing paper on the pad, I stuck the star to the heat sink:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3897.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3897.jpg)

Added the lens:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3898.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3898.jpg)

Then screwed the heat sink cover/cap into place:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3899.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3899.jpg)

Then screwed the blade holder back onto the hilt:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3901.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3901.jpg)

All set for the first completed fire up:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3902.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3902.jpg)

It's alive!!!
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3903.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3903.jpg)

I added one of my blades:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3904.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3904.jpg)

and scrolled through the default colors:
Orange...
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3905.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3905.jpg)

Yellow...
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3906.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3906.jpg)

Green...
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3907.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3907.jpg)

Blue...
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3908.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3908.jpg)

Red...
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3909.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3909.jpg)

Bright blue/teal...
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3910.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3910.jpg)

The switch led also works as intended, and is also nice and bright:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3911.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3911.jpg)

Finished Final Pics coming up in a few minutes. :))

Jay-gon Jinn
05-19-2015, 09:32 PM
Okay, here are the Finished Pictures:

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3912.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3912.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3913.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3913.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3914.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3914.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3915.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3915.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3916.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3916.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3917.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3917.jpg)
This side of the emitter has some defects in the chrome finish. There's nothing I could do about that, except buy another tube and cut a new one.

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3918.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3918.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3919.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3919.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3920.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3920.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3921.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3921.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3922.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3922.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3923.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3923.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3924.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3924.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3925.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3925.jpg)
I left the satin finish on the aluminum. I like the contrast with the chrome on the sink tube.

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3926.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3926.jpg)
I also left all of the scratches I pointed out earlier, as they do give the saber character and give it a well-used, yet well maintained appearance.

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3927.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3927.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3928.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3928.jpg)

Changing the battery is easy...unscrew the pommel:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3930.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3930.jpg)

Give the saber a few gentle shakes to loosen the speaker mount:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3931.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3931.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3932.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3932.jpg)
This will reveal the R.I.C.E. port and the JST plug for the battery.

Pull the R.I.C.E. port out:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3933.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3933.jpg)

Reach in and pull on the JST plug to slide the battery out:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3934.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3934.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3935.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3935.jpg)


After I was finished with it, I put a full size blade in and gave it a few swings and spins....this saber is so light due to the nature of it's construction, that the thin-walled, 34" blade I had in it was really top heavy. I tried out a shorter blade and that made a difference, as did the 7/8" I popped in after that. Then I had to try something else...to counter balance the weight of a blade, a sword has what we call a pommel, right? So, I looked through my parts to see what I had, and I tried a few (a style 3v2, a style 10 and a non-TCSS pommel I have) and this was the best looking one:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3937.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3937.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3938.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3938.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3939.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3939.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3940.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%2041/100_3940.jpg)
Unfortunately, that Acerocket/Orbital Machining Obi TPM is likely out of Zark's price range, since it cost nearly as much as the entire hilt of this saber (not including the electronics, of course). We'll have to try and come up with something else someday, but for now I'll stick to the basic style 4 that is currently intended for this saber. I'll try to get a video made up before the weekend and uploaded to my YouTube channel.... this one needs to be seen and heard to fully appreciate it.

Silver Serpent
05-20-2015, 08:47 AM
Mmm, shiny! Another wonderful saber!

I am also a fan of the occasional scratch and ding in the saber. Partly because it gives the saber a used look, and also because I'm prone to letting the dremel slip. :)

Quixotic Jedi
05-20-2015, 11:23 AM
Another fine looking saber. Ever since I found this forum I've always enjoyed your build threads, thanks for sharing.