'Dies Justitia' Design and build log

[Jagahati]

Howdy guys,

I'm returning to the saber building hobby after a few years away, I made a few amateur and simple sabers a few years ago. While those sabers were kinda "meh" I really enjoyed making them and still take pride in them. I started lurking the forums again and before I knew what had hit me I wanted to build a new saber.

But not like the ones I made before, my goal this time is to make a saber worthy of a true Saber-Smith.

This is the build log for that saber the 'Dies Justitia' or 'Day of Justice'.

I have been inspired by hundreds of other sabers here but the ones I keep coming back to are the star-killer builds, Derelict, and multiple sabers by LDM and Fender Bender. I want to incorporate some of my favorite aspects of these inspiring sabers into my own work.

I am going for a Light-side saber that looks and feels like it was created with combat primarily in mind, a functional and efficient design.

Here are my initial sketches and design ideas, I will likely make a 3D Cad model next to make sure that i can Cram-fu all the elements I want in this design.
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Comments and criticism are not only welcome, but desired.

[Forgetful Jedi Knight]

Welcome back.

I guess the big question here is what do you plan on putting inside of it. As it currently stands, you don't have a lot of room in there.

[Jagahati]

I have an Ignitier 2 I intend to use for sound.
Either a single 18650, or a side-by-side (3.7v) 14500 pack.
A crystal chamber in the ribbed section with the bottom shroud sliding to either reveal or protect it.
Recharge port, 12mm AV if it will fit for my main button and a tactile for the aux.

And yes its gonna be tight, that is why I am thinking spending the time to work it up in CAD will be well worth it so I can at least have a workable plan.

Worst case I would need to extend the 4" section into a 5" section but i feel that makes its proportions less visually appealing.

[Miraluka]

Good luck. I really like the design.

[Jagahati]

With the store closed and feeling the constant itch to work on saber projects I did a little more thinking/sketching and then started on the CAD model.

http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/th_Sketch%204.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/Sketch%204.jpg.html)http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/th_Sketch%205.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/Sketch%205.jpg.html)http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/th_Justita%20top.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/Justita%20top.jpg.html)http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/th_Justita%20Side.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/Justita%20Side.jpg.html)http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/th_Justita%20bottom.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/Justita%20bottom.jpg.html)http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/th_Justita%20cutaway.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/Justita%20cutaway.jpg.html)

That last one is likely to be the most useful or important since this is looking like a pretty tight build and my on-the-fly cram-fu is weak.

~edit for terrible spelling, the bad grammar stays.

[Jagahati]

http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/th_Justita%20cutaway2.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/Justita%20cutaway2.jpg.html)

Looks like my major components will fit. Now I need some measurements for the length of a recharge port and of a 12mm AV switch.

[sgcdialler]

I found a dimension diagram here (http://www.modmaker.co.uk/Mod-Making-Supplies/Switches/12mm-Green-LED-Black-Anodised-Illuminated-Switch-With-Flat-Flush-Actuator) for 12mm switches, and there's a data sheet here (http://www.mouser.com/ProductDetail/Switchcraft/PC722A/?qs=sGAEpiMZZMtUpMOmSPzkH3pHtPOAuW5y) for the 2.1mm Switchcraft jack (I can verify the recharge port measurements tonight, but I'm 98% that page is the same ports TCSS sells).

[Star Bird]

Really Nice Design by the way. I always like other ppl designs more than my own.

[Jagahati]

I found a dimension diagram here (http://www.modmaker.co.uk/Mod-Making-Supplies/Switches/12mm-Green-LED-Black-Anodised-Illuminated-Switch-With-Flat-Flush-Actuator) for 12mm switches, and there's a data sheet here (http://www.mouser.com/ProductDetail/Switchcraft/PC722A/?qs=sGAEpiMZZMtUpMOmSPzkH3pHtPOAuW5y) for the 2.1mm Switchcraft jack (I can verify the recharge port measurements tonight, but I'm 98% that page is the same ports TCSS sells).

AWESOME! Thank you, you just save me tearing apart my daughters saber, something that she does not approve of.

And thanks for the kind words about my design guys, it has been kicking around in my head for a couple years before I got bit by the saber bug again.

[Quixotic Jedi]

I found a dimension diagram here (http://www.modmaker.co.uk/Mod-Making-Supplies/Switches/12mm-Green-LED-Black-Anodised-Illuminated-Switch-With-Flat-Flush-Actuator) for 12mm switches, and there's a data sheet here (http://www.mouser.com/ProductDetail/Switchcraft/PC722A/?qs=sGAEpiMZZMtUpMOmSPzkH3pHtPOAuW5y) for the 2.1mm Switchcraft jack (I can verify the recharge port measurements tonight, but I'm 98% that page is the same ports TCSS sells).

I can't confirm the 12mm anti-vandal dimensions, but the recharge port is exactly what Tim sells.

[Jagahati]

http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/Justita%20switchcharge.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/Justita%20switchcharge.jpg.html)

Looks like I just lucked out. With the Box there is enough room between them when mounted vertically. If it gets too close the soldering lugs could be trimmed down (wouldn't be the first time).

Currently thinking that a Graflex glass eye would make a pretty sick looking kill plug!

Thanks again for your help Quixotic Jedi!

[Forgetful Jedi Knight]

What about the threading between those two parts (blade holder and ribbed section)?

[solaren]

First: Love the design, very similar to one I almost started to make.


What about the threading between those two parts (blade holder and ribbed section)?

Also pretty sure that layout has those two parts meeting in the middle of the LED/heatsink.

[Jagahati]

Also pretty sure that has those two parts meeting in the middle of your LED/heatsink.

I have two different models built one for outside with internals just kinda fudged in, if you look at the cut-a-way view there is space between heat sink holder and the top of the crystal chamber. Yeah by that model it wouldn't work.

FJK is also correct, threads will be drilled though, and yeah that is dicey and will require that the box and charge port be removed to unscrew those two sections. To make the drilling less problematic a set screw will be drilled first to lock the two pieces in place before i drill the larger holes. The set screw should be easy enough to hide under the shroud.

[Forgetful Jedi Knight]

FJK is also correct, threads will be drilled though, and yeah that is dicey and will require that the box and charge port be removed to unscrew those two sections. To make the drilling less problematic a set screw will be drilled first to lock the two pieces in place before i drill the larger holes. The set screw should be easy enough to hide under the shroud.

if you are going through the threaded parts (which is a bad idea), you will also be going through the heat sink assembly (which WON'T work).

[Noyl Wendor]

May work if you got an extension like this http://www.thecustomsabershop.com/75-Male-Female-extension-P776.aspx and mounted your box just as in the above pic. You may have to move a couple pieces down and make your shroud on the box side a bit longer. You would narrowly avoid the heat sink.
But FJK is right, drilling through threads is a tricky thing to do. Small holes okay, but big enough for all the internals in that box. I'm not really sure. If you do pull it off show the pics :D
But give it a second thought before you turn on your drill ;)

[sgcdialler]

I'm relatively sure that that piece is part of his original design, Noyl. I hate to sound like a parrot here, but FJK is right. That layout has a switch attempting to occupy the same space as the heatsink itself, regardless of whether or not you avoid the heatsink housing.

I would suggest bumping from the .75" extension under the emitter to a 2" extension. This will give you a little more room to play without completely ruining the overall proportions of the saber. In these renders I replaced the 4" lower extension with the MHS blank 1 extension (3.7") to get the male and female threads. You could use a thread changer if you stay with the 4" double female though.

Of course drilling through threads is tricky. Drilling through threads and a heatsink though... well let's just say that's not a life you want. :P

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[Jagahati]

http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/Justita%20switchcharge%20Detail.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/Justita%20switchcharge%20Detail.jpg.html)http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/Justita%20switchcharge%20Detail2.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/Justita%20switchcharge%20Detail2.jpg.html)http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/Justita%20switchcharge%20thread%20detail.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/Justita%20switchcharge%20thread%20detail.jpg.html)

Thanks for the feedback guys! Here is a more accurate model of what the parts inside should look like. Gonna need parts in hand to verify for sure if this will work or not.


Also took a couple of pics of my shop and my first ever MHS compatible threads cut!
http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/IMG_4474.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/IMG_4474.jpg.html)http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/IMG_4473.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/IMG_4473.jpg.html)http://i597.photobucket.com/albums/tt51/Jagahati/Dies%20Justitia/IMG_4475.jpg (http://s597.photobucket.com/user/Jagahati/media/Dies%20Justitia/IMG_4475.jpg.html)

Threads are ugly as heck, need to adjust the angle of my compound and use some cutting fluid next time. They did thread smoothly when fitted to a MHS part and cinched tightly at the end. Plan to try internal threads soon, but the rest of my week is already over-booked may not get any saber-ing in.

[Quixotic Jedi]

You set your compound to half the angle of your threads. So for a V thread which is 60 degrees, you set your compound to 30 degrees. Once you set your tool till it just touches your work, you mark that on your cross slide and that is where you return for all your repeat cuts. You use your compound for your infeed until you reach final depth of thread.

Oh, and for safety's sake you never leave the chuck wrench in the chuck. They can, and will, fly out and hurt you!

[Jagahati]

Oh, and for safety's sake you never leave the chuck wrench in the chuck. They can, and will, fly out and hurt you!

Yeah bad habit, good news for me is that the safety shield won't close with the wrench in and my chuck sits too close to the ways to fit on the underside either. I do have the habit of hand-spinning the chuck before firing up the motor to make sure my feed is either engaged or disengaged as it should be, so that exaserbates my bad habit with the wrench.

You are right about the compound, I had mistakenly set it as if I were cutting a square type thread (read all directions dummy) and realized my mistake the first time I carved up my pretty threads on the next pass.

Thanks for the response.

[Quixotic Jedi]

Thanks for the response.

No problem. Been a machinist for 38 years so all this is second nature to me.

[obi2kenobi14]

very cool saber wish the best of luck!