Second Build CF 7.5 With Crystal Chamber

[darth_chasm]

Hey Folks,

I wanted to begin a new thread to chronicle my second build. I've spent the past couple months designing this saber, while building my first, and the majority of the parts are in, so I figured it's a great time to start sharing. I wanted more of a challenge than my first saber, so this one is packed to the gills and has a lot of little custom touches to it. It obviously takes inspiration from Vader's saber, and Madcow's Corran Horn.

The outside is all MHS and features what I think is a cool little "reveal" plate for the crystal chamber inside. The plate will be held in place by set screws for easy removal. The rear grip will also slide off to reveal access to the rice and recharge ports.

Plans for the internals are CF 7.5, tri cree RGRB, 7.4v 18500 pack, 2 tactile switches, crystal chamber, rice and recharge ports, and 1-2 led bar graphs depending on space.

As everything with me, I try to plan out as much as possible before diving in so for this first post here are some renderings of what I'm envisioning.

Feel free to let me know what you think.

http://i12.photobucket.com/albums/a228/mditomo/th_Screen%20Shot%202015-08-14%20at%208.16.46%20PM_zpsegyd1sqz.png (http://s12.photobucket.com/user/mditomo/media/Screen%20Shot%202015-08-14%20at%208.16.46%20PM_zpsegyd1sqz.png.html) http://i12.photobucket.com/albums/a228/mditomo/th_Screen%20Shot%202015-08-14%20at%208.24.51%20PM_zpsmld1jo1u.png (http://s12.photobucket.com/user/mditomo/media/Screen%20Shot%202015-08-14%20at%208.24.51%20PM_zpsmld1jo1u.png.html) http://i12.photobucket.com/albums/a228/mditomo/th_Screen%20Shot%202015-08-14%20at%208.25.55%20PM_zpsq5yzvmxe.png (http://s12.photobucket.com/user/mditomo/media/Screen%20Shot%202015-08-14%20at%208.25.55%20PM_zpsq5yzvmxe.png.html) http://i12.photobucket.com/albums/a228/mditomo/th_Screen%20Shot%202015-08-14%20at%208.17.48%20PM_zpsaars1xdz.png (http://s12.photobucket.com/user/mditomo/media/Screen%20Shot%202015-08-14%20at%208.17.48%20PM_zpsaars1xdz.png.html) http://i12.photobucket.com/albums/a228/mditomo/th_Screen%20Shot%202015-08-14%20at%208.21.59%20PM_zpsdpcmsefg.png (http://s12.photobucket.com/user/mditomo/media/Screen%20Shot%202015-08-14%20at%208.21.59%20PM_zpsdpcmsefg.png.html) http://i12.photobucket.com/albums/a228/mditomo/th_Screen%20Shot%202015-08-14%20at%208.22.42%20PM_zpsus1qugfn.png (http://s12.photobucket.com/user/mditomo/media/Screen%20Shot%202015-08-14%20at%208.22.42%20PM_zpsus1qugfn.png.html)

[Greenie]

That looks pretty awesome! I like the use of the claw mount. I'll be watching this one progress :mrgreen:

Good luck Chasm

[darth_chasm]

Messing around with the crystal chamber. I was worried it wouldn't be bright enough, but it's looking good to me so far. I'm using 1/8 brass compression sleeve and 5/32 brass tube pieces that I cut and sanded as spacers. As pictured, the chamber is 1" from disc to disc.

I have some 18 gauge copper discs coming later today, so hopefully I can get it most of it roughly assembled this weekend. I'll have the black finned piece pictured in the first post by Monday. It's simply an aluminum heat sink that I thought would be a nice design cue for the chamber. We shall see.

http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0493_zpsprwnyd0l.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0493_zpsprwnyd0l.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0494_zps7k2ec8vj.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0494_zps7k2ec8vj.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0495_zpsvv2qhryy.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0495_zpsvv2qhryy.jpg.html)

[darth_chasm]

After two failed tries, I finally got ONE copper piece mostly done. Was also able to finish one of the brass inserts for the claw mount. Doing all this with a Dremel, drill press, files and sandpaper is pretty laborious, but it is rewarding once you get a piece done.
http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0496_zpsj9eoujwg.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0496_zpsj9eoujwg.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_f9fe71c5-3234-4427-b6ce-6a0c1ff725c9_zps0jpahkeo.jpg (http://s12.photobucket.com/user/mditomo/media/f9fe71c5-3234-4427-b6ce-6a0c1ff725c9_zps0jpahkeo.jpg.html)

[darth_chasm]

I decided to switch gears today and move from the crystal chamber to the emitter and chamber plate.

I was having an extremely hard time with my pipe cutter walking, so took out the hack saw and did it the slow way. The screwed up piece has an interesting look to it so I'll hold on to it for something in the future.

http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0499_zpsmdeulgki.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0499_zpsmdeulgki.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0498_zpsc3u44wfa.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0498_zpsc3u44wfa.jpg.html)

After I cut the pieces to length I drilled the fastener holes. I started out with these spot bits then moved on to the 6-32 bit.

http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0502_zpst9iilsrw.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0502_zpst9iilsrw.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0503_zpsfxgw6cwo.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0503_zpsfxgw6cwo.jpg.html)

After that, I cut, filed, and sanded the plate, half shroud and emitter. About 8 hours worth of hand work. Not perfect and nowhere near a machine finish but I'm extremely happy with the outcome. I decided to forego the drill holes in the half shroud as I felt my skill and tools lack the precision I want.

http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0504_zpswu3xvcom.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0504_zpswu3xvcom.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0505_zpszwsettsi.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0505_zpszwsettsi.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0506_zpsrd1qxrrj.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0506_zpsrd1qxrrj.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0507_zpsfc5ouxrz.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0507_zpsfc5ouxrz.jpg.html)

Updates to come...:p

[Miraluka]

That's looking pretty.

[darth_chasm]

That's looking pretty.

Thank you!

[darth_chasm]

That looks pretty awesome! I like the use of the claw mount. I'll be watching this one progress :mrgreen:

Good luck Chasm

Thanks Greenie!

[darth_chasm]

Time for some updates.


I spent the week toying around with the crystal chamber after some parts arrived on Monday. Specifically, the aluminum heatsink that I plan on using as the holder for the crystal. It's been a mostly experimental process to see how things will look and fit together.


The first idea was to use the heatsink as both the holder for the led and the crystal. So I first drilled a 7/32 hole, then counter-bored a 15/64 hole leaving a tiny lip at the bottom of the heatsink for the led to sit on. Then I counter-bored a 5/16 hole about half way down for the crystal to sit in. It seemed to fit together nicely, but I wasn’t entirely happy with it. I couldn’t really see a way to make the led secure without using hot glue which would end up covering the lens.


http://i12.photobucket.com/albums/a228/mditomo/th_cc-base-1_zpsqziwvqdr.jpg (http://s12.photobucket.com/user/mditomo/media/cc-base-1_zpsqziwvqdr.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cc-base-2_zpsrwjlgdvc.jpg (http://s12.photobucket.com/user/mditomo/media/cc-base-2_zpsrwjlgdvc.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cc-base-3_zpsbsqfowwq.jpg (http://s12.photobucket.com/user/mditomo/media/cc-base-3_zpsbsqfowwq.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cc-base-5_zpsfrwhta7p.jpg (http://s12.photobucket.com/user/mditomo/media/cc-base-5_zpsfrwhta7p.jpg.html)


The next idea was to use one of the blank chassis discs as the led holder and to mount the heatsink to the disc. So I went about drilling all the holes and creating a seat for the led in the center. But I quickly realized that I was doing this with a 1.24” disc and I need the base disc to be the 1.31” locking type. Unfortunately, those aren’t sold as blanks, so the led “seat” idea wasn’t going to work in the final.


http://i12.photobucket.com/albums/a228/mditomo/th_cc-base-6_zpsjkwvfmvr.jpg (http://s12.photobucket.com/user/mditomo/media/cc-base-6_zpsjkwvfmvr.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cc-base-7_zpsrt7jrjs4.jpg (http://s12.photobucket.com/user/mditomo/media/cc-base-7_zpsrt7jrjs4.jpg.html)


Then I got the idea to use a 5mm led holder as the holder for the led…brilliant right? But in this case I am using it a bit backwards and dropping the led in leads first. The threaded end of the holder fits perfectly through the predrilled hole of the chassis discs. Using the holder backwards allows me to use the heatsink as the nut. I am waiting for a 5/16-32 tap to come in and I will tap the hole in the heatsink and screw it onto the holder with the chassis disc between. As you can see below, everything seems to fit nicely. I have a few ideas to secure the led in the holder so it doesn’t rattle around. I can put hot glue where the leads come out, use a small piece of heat shrink around the led itself to snug it up inside the shaft, or use a small piece of stiff foam on the leads. I’ll test them all once I have the heat sink tapped.


http://i12.photobucket.com/albums/a228/mditomo/th_cc-base-01_zpstequkql2.jpg (http://s12.photobucket.com/user/mditomo/media/cc-base-01_zpstequkql2.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cc-base-02_zpsq3tlooiy.jpg (http://s12.photobucket.com/user/mditomo/media/cc-base-02_zpsq3tlooiy.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cc-base-04_zps9ubv7e6h.jpg (http://s12.photobucket.com/user/mditomo/media/cc-base-04_zps9ubv7e6h.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cc-base-03_zps3y9tbodu.jpg (http://s12.photobucket.com/user/mditomo/media/cc-base-03_zps3y9tbodu.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0522_zpsqj08s52q.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0522_zpsqj08s52q.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cc-base-05_zpsi4lnrgs2.jpg (http://s12.photobucket.com/user/mditomo/media/cc-base-05_zpsi4lnrgs2.jpg.html)


I was also able to work on the claw mount/guard a little more. I have the brass inserts for the top two slots cut and placed with temporary socket cap screws. I am waiting for some low profile, black oxide socket cap screws to come in which I will use in place of the ones you see here. The d-ring is mounted to a piece of 0.25” brass square bar cut to size. I’m not crazy about the d-ring I have in there now, so I may try to form my own that will fit a little better. I’m also not crazy about how much it rattles, so I’m trying to come up with a way to reduce that. Maybe tape or heat shrink.


http://i12.photobucket.com/albums/a228/mditomo/th_cm-2_zps83bjikjx.jpg (http://s12.photobucket.com/user/mditomo/media/cm-2_zps83bjikjx.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cm-1_zpslfx30ki9.jpg (http://s12.photobucket.com/user/mditomo/media/cm-1_zpslfx30ki9.jpg.html)


Well, thats it for now. I’ll probably have more updates next weekend. Thanks for looking.

[darth_chasm]

Here's a shot of the chassis mocked up. I had to use some cardboard for the battery and CEX, still waiting on those. I'm feeling pretty confident with the size and everything fitting inside the hilt nicely.

http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0531_zpspxtwroyn.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0531_zpspxtwroyn.jpg.html)

My 5/16-32 tap came in today. I tapped the heatsink - "chamber fan" moving forward - and mounted it to the 5mm led holder and chassis disc. Fits like a charm.

http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0533_zpsvcasze4t.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0533_zpsvcasze4t.jpg.html)

And here's a shot of the custom housing I designed for the r/c port, rice port and bar graph. Again, everything fits beautifully.

http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0532_zpscxjypqml.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0532_zpscxjypqml.jpg.html)

[darth_chasm]

I was able to work on the crystal chamber some more this weekend. I started out trying to fabricate the copper “radiator” discs out of 16 gauge jewelry discs, but wasn’t having much luck with all the holes lining up and the pieces sliding onto the 4-40 rods smoothly. The discs were just too thin to put in a vise and clamps didn’t help either. They just kept spinning and twisting. I then tried some copper sheet thinking I could cut some squares and place them into the vise to drill the holes and then use a hole saw to cut the discs out. No luck either. Same spinning and bending issues.


I was about to give up on the discs and move onto another idea, but as a last ditch effort, I ordered some copper washers for 1/2” bolts. They measured about 1.375” OD. I spent a total of about 10 hours hand sanding and tuning them all down to roughly 1.245” OD. Then I bolted them all together and placed the nut in the vise and drilled all the discs at once. After a little filing they all fit nicely onto the rods and everything slid right into the hilt. You’ll see a notch in them that I plan to file away.


Next I fabricated the copper piping. These are made up of telescoping hobby tubes of 3 increasing OD’s. I cut them at random lengths to create some interesting “architecture” in the chamber. The thinest tube fits loosely through the pre-drilled holes in the TCSS chassis discs. I used the next size up as makeshift nuts to hold them in place. Then I capped them all with the largest size to create some dimension. A tiny drop of crazy glue holds all the pieces together.


After that I treated the top chassis disc and “chamber fan” with a heavy dose of Aluminum Black. The bottom disc is just there for mock up purposes. The final will be the locking type and I’ll treat that one as well.


Here is a shot of all the pieces. We have two TCSS chassis discs, 8 copper pipes, 1 chamber fan, 3 radiator discs, 9 1/8th brass compression sleeves, 6 brass spacers, 1 5mm led holder, 1 5mm RGB led, 1 quartz crystal, and 1 brass insert thingy. It’s some sort of furniture insert, but I can’t remember exactly what it is.

http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0535_zpsmv2g2zcw.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0535_zpsmv2g2zcw.jpg.html)


And here are some details of it all assembled. I still have some fine tuning to do but it is looking pretty awesome. Sorry I don’t have any shots of it lit. One of the leads from my test batteries came loose and the connection spot is to small to re-solder. I’ll try to get some illuminated shots up soon.

http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0536_zpsafncumgs.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0536_zpsafncumgs.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0537_zpsf8qpolup.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0537_zpsf8qpolup.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0538_zpsz10esel3.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0538_zpsz10esel3.jpg.html)


That's it for now. See you soon.

[snilam]

Looking really nice, your CC is coming along great your hard work is showing. I'll be following your thread keep it up!

[darth_chasm]

Looking really nice, your CC is coming along great your hard work is showing. I'll be following your thread keep it up!

Thank you sir!

[.: SparrowHawk :.]

Wow, most impressive build so far darth_chasm! I'm loving how the design for the crystal chamber is shaping up, the "fan" and the copper tubes and radiator disks are just awesome. By the way, what CAD/rendering software are you using?

[darth_chasm]

Wow, most impressive build so far darth_chasm! I'm loving how the design for the crystal chamber is shaping up, the "fan" and the copper tubes and radiator disks are just awesome. By the way, what CAD/rendering software are you using?

Thanks!

It's Autodesk 123D...freeware. I wouldn't classify it as CAD software. It's more of a tinkerer's tool with a less robust tool/feature set than high-end software, but it does what it needs to do for these purposes. You can also export STL files for 3D printing. And, if I'm not mistaken, I think you can export 2D drawings with a premium upgrade. The materials are very limited, but you can get a good idea of looks from whats available. Aligning objects is less intuitive than I like but with the Snap tool and a little math you can get good results.

I believe the next level up would be Autodesk Inventor or Inventor Fusion. I have one of them but haven't even opened it.

I have to admit that I do the more complex shapes in Adobe Illustrator first and export them as SVG's. Then import them into 123D and extrude, lathe/rotate, etc as needed. It's simply easier for me that way as I've been using Illustrator for nearly 20 years and can crank them out without even thinking about it :)

Hope this helps.

[.: SparrowHawk :.]

Thanks!

It's Autodesk 123D...freeware. I wouldn't classify it as CAD software. It's more of a tinkerer's tool with a less robust tool/feature set than high-end software, but it does what it needs to do for these purposes. You can also export STL files for 3D printing. And, if I'm not mistaken, I think you can export 2D drawings with a premium upgrade. The materials are very limited, but you can get a good idea of looks from whats available. Aligning objects is less intuitive than I like but with the Snap tool and a little math you can get good results.

I believe the next level up would be Autodesk Inventor or Inventor Fusion. I have one of them but haven't even opened it.

I have to admit that I do the more complex shapes in Adobe Illustrator first and export them as SVG's. Then import them into 123D and extrude, lathe/rotate, etc as needed. It's simply easier for me that way as I've been using Illustrator for nearly 20 years and can crank them out without even thinking about it :)

Hope this helps.

Ah yes, it does help! Autodesk 123D, I've been seeing it used around quite a lot, I'll have to check it out! The exporting capability for STLs is nice. I've used SketchUp for some years now, and while it's okay for general modeling needs, some of the tools and commands are just awkward to work with (yep, aligning objects is a pain in the butt), so I've been curious about using an Autodesk software.

Hmm I hadn't thought about using Illustrator for the complex stuff, then importing the vector file for the 3D work, but that totally makes sense! Especially for those curved pieces on say a shroud design. The hotkeys for the Adobe suite are much easier to use than my experience with Sketchup, so yet another thing to try out. Thanks for the tips! :D

[darth_chasm]

No problem. Actually, shrouds are easier to do within the 3D program. Just make a tube and use a block or two as subtraction objects. There's no real way you can accomplish that with a 2D vector and say an extrude or lathe function. The more complex shapes like a grooved grip, a disc with holes in specific spots, or my "chamber fan" are what I use AI for. 123D does have an array tool, but like I said I can do it in AI in a fraction of the time.

One note on SVG's from AI to 123D...For some reason AI exports them a little wonky using pixels as the unit of measure, so if you export a drawing at 100% it will import into 123D at an enormous size. The trick is to scale the AI drawing by multiplying its dimensions by 0.3528 and then importing it into 123D. Presto, to scale sketches for you to play with.

[.: SparrowHawk :.]

I've always wondered about the subtraction object approach, I see how that's the best way for those compound shapes. Unfortunately the subtraction function on Sketchup is only in the pro license so I haven't learned it yet, but fortunately it seems to be in 123D Design (http://www.123dapp.com/design)freeware (ironically, the first of the Autodesk promo renders is a very Sith inspired lightsaber! Likely belonging to someone on the forums... So I basically have to try it out).

Huh, pixels for units of measurement in AI exported vector files? Very wonky indeed, I'll keep that scale conversion in mind! Looking forward to following your build :)

[CET]

http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0535_zpsmv2g2zcw.jpg

I've seen the brass "crescent" pieces before. What are they called and where do you get them?

[darth_chasm]

I've seen the brass "crescent" pieces before. What are they called and where do you get them?

They're actually copper and all custom made. Check the second paragraph in post #11 above for how I made them. I got the washers from McMaster.

[darth_chasm]

Made some updates to the chamber design. I felt there was too much copper between the discs and tubes, so I redesigned the tube set up to have some brass sections. I also added some 1/16th brass rod to connect a few of the tubes from top to bottom. I like how it creates an illusion of circuitry. I also got the proper chassis disc this week, so that got treated with Aluminum Black to match the top disc.

Here is the final design all assembled and illuminated! I'm pretty happy with this so I am going to move on to the hilt now.

http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0551_zpsdnzc8dbt.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0551_zpsdnzc8dbt.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0550_zps1uktcm02.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0550_zps1uktcm02.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0552_zpsiyrkp9nz.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0552_zpsiyrkp9nz.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0557_zpsoevgehro.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0557_zpsoevgehro.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0556_zpshlgmatfx.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0556_zpshlgmatfx.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMG_0559_zpsgcmqndml.jpg (http://s12.photobucket.com/user/mditomo/media/IMG_0559_zpsgcmqndml.jpg.html)

[Generic Jedi]

Nice work on your crystal chamber. It looks awesome!

[darth_chasm]

Nice work on your crystal chamber. It looks awesome!

Thank you!

[Greenie]

Excellent work chasm, I like the brass and copper pipe work, nice double set bends. Good use of the washers for the 'radiator vanes'. I look forward to more progress reports :mrgreen:

[.: SparrowHawk :.]

Looking totally awesome, darth_chasm! I think the brass additions did the trick. This crystal chamber is getting way too real, be careful you don't cut through a wall when it's all assembled. ;-)

[darth_chasm]

Thanks guys!


Here’s another update.


I moved on to the customizations for the hilt . I started out cutting the grooved sleeve to length for both the rear grip and switch collar. Once the pieces were cut i sanded them down and leveled them off.


http://i12.photobucket.com/albums/a228/mditomo/th_mitre_zpsemuxzixl.jpg (http://s12.photobucket.com/user/mditomo/media/mitre_zpsemuxzixl.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_sanding_zpszzdbpb4y.jpg (http://s12.photobucket.com/user/mditomo/media/sanding_zpszzdbpb4y.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_level_zps0aulzvf8.jpg (http://s12.photobucket.com/user/mditomo/media/level_zps0aulzvf8.jpg.html)


Then I started on the slot window in the rear grip for the bar graph, something I had been putting off for quite some time. I first marked a series of lines for the drill. Then, with the suggestions of a few here on the forums, I used a piece of aluminum angle as a jig to guide the vise and drilled the holes. After some filing, viola a nice neat slot. Then I drilled the hole for the set screw.


http://i12.photobucket.com/albums/a228/mditomo/th_slot%20marks_zpsahcxhdzk.jpg (http://s12.photobucket.com/user/mditomo/media/slot%20marks_zpsahcxhdzk.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_press_zpsyelhhnzd.jpg (http://s12.photobucket.com/user/mditomo/media/press_zpsyelhhnzd.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cut%20pieces%201_zpsgn7sahhw.jpg (http://s12.photobucket.com/user/mditomo/media/cut%20pieces%201_zpsgn7sahhw.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cut%20pieces%202_zps2maku6hx.jpg (http://s12.photobucket.com/user/mditomo/media/cut%20pieces%202_zps2maku6hx.jpg.html)


Then I moved on to the plate that will cover the crystal chamber window. pretty simple process; saw, Dremel, files, sand paper. Again the hole for the set screw.


http://i12.photobucket.com/albums/a228/mditomo/th_plate%201_zpsagm8zck4.jpg (http://s12.photobucket.com/user/mditomo/media/plate%201_zpsagm8zck4.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_plate%202_zpsvnpwjsuj.jpg (http://s12.photobucket.com/user/mditomo/media/plate%202_zpsvnpwjsuj.jpg.html)

Things left to do are drill the set screw holes in the switch collar and hilt, drill the r/c and rice port holes in the hilt, cut the button slots in the collar, cut the bar graph slot in the hilt, and cut the crystal chamber window in the hilt.

Here are a few shots of it all mocked up. I have to admit, it is looking really awesome. I am so happy with the outcome so far.


http://i12.photobucket.com/albums/a228/mditomo/th_mock%20up_zpsazjexmj3.jpg (http://s12.photobucket.com/user/mditomo/media/mock%20up_zpsazjexmj3.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_full%20hilt1_zpscuhbmod4.jpg (http://s12.photobucket.com/user/mditomo/media/full%20hilt1_zpscuhbmod4.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_emitter%20end%201_zpsefsu7lun.jpg (http://s12.photobucket.com/user/mditomo/media/emitter%20end%201_zpsefsu7lun.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_emitter%20end%202_zpsoet8zdzq.jpg (http://s12.photobucket.com/user/mditomo/media/emitter%20end%202_zpsoet8zdzq.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_emitter%20end%203_zpsjykugsin.jpg (http://s12.photobucket.com/user/mditomo/media/emitter%20end%203_zpsjykugsin.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_pommel%20end%201_zpsgk1dches.jpg (http://s12.photobucket.com/user/mditomo/media/pommel%20end%201_zpsgk1dches.jpg.html)

[darth_chasm]

I made a lot of progress this week and weekend after a lot of "measure 9 times, cut once, fix what you goofed." All of the major custom work on the hilt is done! I can finally give my hands a well deserved rest.


I fabricated the switches this week. If you missed it and are interested, I posted a how-to here (http://forums.thecustomsabershop.com/showthread.php?18426-Walk-Through-Decorative-Brass-Heads-For-Tactile-Switches). After making the switches, I drilled the holes in both the 3” extension and the grooved switch collar. Here I am testing the fit. Hah you can see I get a little obsessive with writing myself notes. The other marks you see are the layout for the crystal chamber window. I didn’t get any progress pictures on that but you'll see the outcome below.


http://i12.photobucket.com/albums/a228/mditomo/th_05456F59-81D5-4680-BC2C-1C3FBCE9F349_zps1xt7745n.jpg (http://s12.photobucket.com/user/mditomo/media/05456F59-81D5-4680-BC2C-1C3FBCE9F349_zps1xt7745n.jpg.html)


Here I am using the slot I previously cut in the grip as a template for cutting the slot in the 6” extension. In hindsight, I should have done them at the same time but the outcome was more than acceptable. I also learned for next time it would be better to drill the two end holes first, then the holes in the middle. You can see here I started at one end and moved up.

http://i12.photobucket.com/albums/a228/mditomo/th_F285BBED-22E5-4D6F-A0C6-CB3BF42BACA6_zpsyxtioim5.jpg http://i12.photobucket.com/albums/a228/mditomo/th_7A571E8D-039F-4350-BBD1-9DC24CBE746C_zps5rlvzmzk.jpg (http://s12.photobucket.com/user/mditomo/media/7A571E8D-039F-4350-BBD1-9DC24CBE746C_zps5rlvzmzk.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_268D6EB3-A391-44CB-B70B-C28AD3A07B83_zpsxbpon53p.jpg (http://s12.photobucket.com/user/mditomo/media/268D6EB3-A391-44CB-B70B-C28AD3A07B83_zpsxbpon53p.jpg.html)


After the switch holes, bar graph slot, chamber window, access holes for the ports, and set screws were done I assembled everything, including the chassis, to see how it all fit. Not bad at all.


http://i12.photobucket.com/albums/a228/mditomo/th_B55EE186-6614-4F50-9620-A6E0032CBC35_zpsil4psj7m.jpg (http://s12.photobucket.com/user/mditomo/media/B55EE186-6614-4F50-9620-A6E0032CBC35_zpsil4psj7m.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_14B0EB09-0197-422A-B071-229757C61D5B_zpshprmcjhl.jpg (http://s12.photobucket.com/user/mditomo/media/14B0EB09-0197-422A-B071-229757C61D5B_zpshprmcjhl.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_13E2E3BE-1DE9-400B-A284-453871CE8C49_zpsrsazzmol.jpg (http://s12.photobucket.com/user/mditomo/media/13E2E3BE-1DE9-400B-A284-453871CE8C49_zpsrsazzmol.jpg.html)


I began to dislike the original half shroud I had and decided a simple sleeve was the way I wanted to go. Here you can see I added some copper coil as a nice little design element. I think it’s kind of cool.


http://i12.photobucket.com/albums/a228/mditomo/th_0D1A5368-8025-4A7F-B031-861767A78876_zpsj8wovuox.jpg (http://s12.photobucket.com/user/mditomo/media/0D1A5368-8025-4A7F-B031-861767A78876_zpsj8wovuox.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_239ABD6C-1ABC-49DD-B702-2755EEDD4989_zpsuth38z8c.jpg (http://s12.photobucket.com/user/mditomo/media/239ABD6C-1ABC-49DD-B702-2755EEDD4989_zpsuth38z8c.jpg.html)


Here are some close ups of the the button install. You can see in the second picture I am using a double switch ring to secure the switches and that sits directly under the led module. The two holes at the top are where the switch and main led wires will run through.


http://i12.photobucket.com/albums/a228/mditomo/th_A64A7869-7D4A-457A-9D81-763FA3C88EE6_zpshinzkndn.jpg (http://s12.photobucket.com/user/mditomo/media/A64A7869-7D4A-457A-9D81-763FA3C88EE6_zpshinzkndn.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_42CDDBD2-919F-4FAF-8ACF-9FE30E1F1620_zpslswmtzp2.jpg (http://s12.photobucket.com/user/mditomo/media/42CDDBD2-919F-4FAF-8ACF-9FE30E1F1620_zpslswmtzp2.jpg.html)


Now for what I think are some of the coolest features of the design.


The chamber plate, rear grip, and switch collar are all held in by set screws in the hilt. The way these are set up is that when turned to the left (unscrewed) they will create pressure locking each piece in place. A little technique I picked up from watching Madcow’s videos.


Releasing the pressure on the bottom screw here allows you to slide the plate down ultimately reveling the crystal chamber.


http://i12.photobucket.com/albums/a228/mditomo/th_74BA38C1-7378-4C46-95DD-F10C99A08380_zpsymqu0z04.jpg (http://s12.photobucket.com/user/mditomo/media/74BA38C1-7378-4C46-95DD-F10C99A08380_zpsymqu0z04.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_14A557A1-CF05-4DAF-89A8-6BD039F642D9_zpstljqfp2q.jpg (http://s12.photobucket.com/user/mditomo/media/14A557A1-CF05-4DAF-89A8-6BD039F642D9_zpstljqfp2q.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_98EE5DC4-E5FE-4F88-96F4-B8148295693F_zpsfmk93yde.jpg (http://s12.photobucket.com/user/mditomo/media/98EE5DC4-E5FE-4F88-96F4-B8148295693F_zpsfmk93yde.jpg.html)


The rear grip works in the same fashion to allow access to the recharge and rice ports.


http://i12.photobucket.com/albums/a228/mditomo/th_769B14F8-58D3-435F-9997-9227267893BE_zps5ek0ywmn.jpg (http://s12.photobucket.com/user/mditomo/media/769B14F8-58D3-435F-9997-9227267893BE_zps5ek0ywmn.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_89B7BBA8-2D4D-46C6-AE3B-F9CFB88C305F_zps2bpdrqxr.jpg (http://s12.photobucket.com/user/mditomo/media/89B7BBA8-2D4D-46C6-AE3B-F9CFB88C305F_zps2bpdrqxr.jpg.html)


Here’s the hilt with both pieces in reveal mode.


http://i12.photobucket.com/albums/a228/mditomo/th_FA1F27B4-847B-4ED6-A61F-6AC6350D865F_zpsjrsoheez.jpg (http://s12.photobucket.com/user/mditomo/media/FA1F27B4-847B-4ED6-A61F-6AC6350D865F_zpsjrsoheez.jpg.html)


And a quickie of the chassis sans electronics.


http://i12.photobucket.com/albums/a228/mditomo/th_40C0FF68-2DDA-474F-8D96-B8C3258E683E_zpsblyevn6x.jpg (http://s12.photobucket.com/user/mditomo/media/40C0FF68-2DDA-474F-8D96-B8C3258E683E_zpsblyevn6x.jpg.html)


Here are some shots of the chamber illuminated. I’m loving the way this looks.


http://i12.photobucket.com/albums/a228/mditomo/th_E1214D02-B020-44D6-84C5-AE13F21FBE61_zpsgx7k2wro.jpg (http://s12.photobucket.com/user/mditomo/media/E1214D02-B020-44D6-84C5-AE13F21FBE61_zpsgx7k2wro.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_B3D4443C-330F-4782-9DFB-35E3A06EFEA0_zpslcnmkmvm.jpg (http://s12.photobucket.com/user/mditomo/media/B3D4443C-330F-4782-9DFB-35E3A06EFEA0_zpslcnmkmvm.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_82044A5F-7E3E-4F1B-86AA-31E6DB2CDD6E_zpsr1mjdo9p.jpg (http://s12.photobucket.com/user/mditomo/media/82044A5F-7E3E-4F1B-86AA-31E6DB2CDD6E_zpsr1mjdo9p.jpg.html)


I also had a little time to test out ARKM’s Saltwater Etching Tut (http://forums.thecustomsabershop.com/showthread.php?13430-ARKM-s-Saltwater-Etching-Tutorial) as I plan on doing some etching to the hilt. I used a 6 volt lantern battery instead of the 4 D cells mentioned. And for this test I just used electrical tape as the resist. Below was the result after 20-25 minutes in the solution. You can see it produces a pretty deep etch in very little time.


http://i12.photobucket.com/albums/a228/mditomo/th_A6D0649B-0F56-4A69-80E8-060CCCF73911_zpsfm8qpnj2.jpg (http://s12.photobucket.com/user/mditomo/media/A6D0649B-0F56-4A69-80E8-060CCCF73911_zpsfm8qpnj2.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_478CF4BD-E88E-42E9-B009-17219F505F3E_zpsfnmiyelm.jpg (http://s12.photobucket.com/user/mditomo/media/478CF4BD-E88E-42E9-B009-17219F505F3E_zpsfnmiyelm.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_695A3835-22AA-4EFF-88F3-2BB8DF5693F7_zpsjeoqzwed.jpg (http://s12.photobucket.com/user/mditomo/media/695A3835-22AA-4EFF-88F3-2BB8DF5693F7_zpsjeoqzwed.jpg.html)


Next steps are some much needed touch up on the cuts, sanding, and polishing. Then I’ll go on to etching and painting. And once the CEX’s are back I can begin the electronics install.

[Silver Serpent]

Looking good there. I like the slide-to-reveal parts of your saber. That's a nifty design element. Just be mindful that those areas will be very likely to get scratched/scuffed up, especially if there's ANY dirt on that part of the hilt.

[darth_chasm]

Looking good there. I like the slide-to-reveal parts of your saber. That's a nifty design element. Just be mindful that those areas will be very likely to get scratched/scuffed up, especially if there's ANY dirt on that part of the hilt.

Thanks SS. And a very good concern to bring up. I did think of it and in addition to obsessively wiping the thing down, I have a few ideas that I want to test on some scrap pieces. They may end up being a bust but we shall see.

[darth_chasm]

Well looks like it's time for an update, not a very big one though.

I soldered on my surface mount resistors for the bar graph and crystal chamber led. It was actually a lot easier than I anticipated. I picked up a set of visor magnifiers with 1.5 - 3X magnification and found them invaluable in the process. Also a good set of ESD tweezers goes a long way. You'll see in the 2nd pic below the pads that didn't need resistors are bridged with a small piece of wire.

http://i12.photobucket.com/albums/a228/mditomo/th_CC9415D1-46D3-4B65-8654-FECAFDE79C93_zps4kqkysda.jpg (http://s12.photobucket.com/user/mditomo/media/CC9415D1-46D3-4B65-8654-FECAFDE79C93_zps4kqkysda.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_cd6f988d-56bf-4010-9719-1cf06938a350_zpswdbcfaoh.jpg (http://s12.photobucket.com/user/mditomo/media/cd6f988d-56bf-4010-9719-1cf06938a350_zpswdbcfaoh.jpg.html)

After that I wired up the CF for a test run of everything except the main led. Fired everything up and it worked! {obligatory WOO HOO!!}

I made a custom blade plug from an electric razor screen per ARKM's awesome original idea. I used a TCSS blade plug that I cut down and bored out a bit using a mini hacksaw and dremel. Then I ground down the outer lip of the shaver screen and press fit it into the blade plug. I used a piece of a white plastic bag behind the screen to diffuse the light, the screen WILL NOT save your eyes. I went with it upside down as I really liked the look of the underside. They come in packs of three so I am going to try a couple other things.

http://i12.photobucket.com/albums/a228/mditomo/th_9D037F5B-2134-4C8D-9662-C57BD3FDBBA0_zpszwjsh3yh.jpg (http://s12.photobucket.com/user/mditomo/media/9D037F5B-2134-4C8D-9662-C57BD3FDBBA0_zpszwjsh3yh.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_76BCE9B3-9B2D-46E3-B51B-13B0CC1A4ECE_zpssfixurvn.jpg (http://s12.photobucket.com/user/mditomo/media/76BCE9B3-9B2D-46E3-B51B-13B0CC1A4ECE_zpssfixurvn.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_622C9498-E02E-42E5-A4F9-8D3E00FE18DC_zpsbjtlovif.jpg (http://s12.photobucket.com/user/mditomo/media/622C9498-E02E-42E5-A4F9-8D3E00FE18DC_zpsbjtlovif.jpg.html)

I started my etching and the results are pretty cool. I still have some more to do but heres the start of it. This time around I used some vinyl I had cut as the resist. This is a really fun process and I would recommend people try it if they haven't yet.

http://i12.photobucket.com/albums/a228/mditomo/th_655004FC-1388-4067-893D-11972BDE480F_zpsu3rfi1sv.jpg (http://s12.photobucket.com/user/mditomo/media/655004FC-1388-4067-893D-11972BDE480F_zpsu3rfi1sv.jpg.html)

I've been going back and forth on what I should do about the finish on the saber. Originally I wanted it powder coated, but for various reasons it's just not a feasible solution. Then I thought ok I'll paint it. Problem is, I live in an apartment in NYC with no place to paint without making myself very sick. So I started reading about anodizing and decided to give it a try for two main reasons. 1) I can do it at home without much risk (non-acid method) and 2) it has the potential to protect against damage from the sliding features of my design.

I picked up this nifty bench power supply to help regulate the current and will give a try on some scrap pieces this weekend. I'll report back when I have results.

http://i12.photobucket.com/albums/a228/mditomo/th_180E66AB-9F12-4D04-AA49-BCF95DA4F41A_zpsrxn1pjot.jpg (http://s12.photobucket.com/user/mditomo/media/180E66AB-9F12-4D04-AA49-BCF95DA4F41A_zpsrxn1pjot.jpg.html)

See you soon…

[Greenie]

Great update chasm. Once again I'm liking your work. Nice etching, cool design, is it acid or saltwater?
'ARKMs razor' as I'm calling it now, is a good idea.

12055

I did the same :mrgreen:

Ok. I just went back and read properly. Saltwater then

[darth_chasm]

Great update chasm. Once again I'm liking your work. Nice etching, cool design, is it acid or saltwater?
'ARKMs razor' as I'm calling it now, is a good idea.

12055

I did the same :mrgreen:

Ok. I just went back and read properly. Saltwater then

nice man! You even did it upside down haha.

[darth_chasm]

Ok so the first DIY anodizing test was a 50/50 success/failure. A success in so far as the piece did in fact anodize producing a significantly stronger layer on the outside. Holds up to a fingernail test as well as the sharp end on some metal wire at varying degrees of pressure.

The failure comes in the way of not really getting any color to set in the piece.

I've noted a few things that I need to adjust or improve upon. First and most importantly, cleaning the piece. It's apparent that the metal must be entirely clean and free of all contaminants. I scrubbed this test piece for fifteen minutes with a scotch bright pad and some soap and water. Next test I will wipe the piece down in acetone, boil it in hot water and scrub even longer.

Second, my etchant was not 100% sodium hydroxide (lye), so I think that may have had an effect by way of contamination. Next test will use 100%

Third, I went with a constant voltage approach on this test. Further reading has revealed that a constant current is highly recommended.

Fourth, I'm not sure how well my pieces remained in contact with the leads. I will have to improve my rigging.

Fifth, I used Rit Dye More Dye in Graphite (black). I have read that black in particular is not very easy color to dye with. I have ordered some authentic anodizing dye and will try that in the next test.

Here's the set up I used today. Etchant, Rinse 1, Anodize Solution, Rinse 2, Dye (i ended up doing this on the stove top to maintain 140? F).

http://i12.photobucket.com/albums/a228/mditomo/th_50048D7B-B241-4332-9486-D8BE7BB8F1F7_zps4l5dxx9c.jpg (http://s12.photobucket.com/user/mditomo/media/50048D7B-B241-4332-9486-D8BE7BB8F1F7_zps4l5dxx9c.jpg.html)

Etchant and Anodize Solution

http://i12.photobucket.com/albums/a228/mditomo/th_0032C881-2955-431F-A791-361CD8E9566D_zpsrhpludwe.jpg (http://s12.photobucket.com/user/mditomo/media/0032C881-2955-431F-A791-361CD8E9566D_zpsrhpludwe.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_0E95BB6E-F5F4-456E-803D-83594425110E_zps41jgc480.jpg (http://s12.photobucket.com/user/mditomo/media/0E95BB6E-F5F4-456E-803D-83594425110E_zps41jgc480.jpg.html)

And the terribly awful looking outcome. Third pic is with flash. Fourth pic is side by side with an untreated piece.

http://i12.photobucket.com/albums/a228/mditomo/th_DC269C4B-1C18-4B10-8589-24047FB39F12_zps9cj5p5dj.jpg (http://s12.photobucket.com/user/mditomo/media/DC269C4B-1C18-4B10-8589-24047FB39F12_zps9cj5p5dj.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_8B216DC4-91FE-4D56-9B0D-5731950810D8_zpsblcze2fo.jpg (http://s12.photobucket.com/user/mditomo/media/8B216DC4-91FE-4D56-9B0D-5731950810D8_zpsblcze2fo.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_ED903444-EB22-4C99-90BE-0C9B346B70DC_zpshqductpo.jpg (http://s12.photobucket.com/user/mditomo/media/ED903444-EB22-4C99-90BE-0C9B346B70DC_zpshqductpo.jpg.html)http://i12.photobucket.com/albums/a228/mditomo/th_14DCD238-B240-4D08-8253-34DBC305536E_zpsdjcstwv0.jpg (http://s12.photobucket.com/user/mditomo/media/14DCD238-B240-4D08-8253-34DBC305536E_zpsdjcstwv0.jpg.html)

[darth_chasm]

Alright, I guess I'm way too impatient or just having too much fun. I didn't want to wait for the anodizing dye to do a second test so I did 2 more pieces today.

Things done different:

- Bypassed the lye and went straight to the anodize solution after cleaning.

- Cleaning involved a fresh sanding, wipe down with acetone, scrub with scotch bright, soap & water (10 min), boiling (5 min), second scrub with scotch bright, soap & water (10 min) and rinse in distilled water.

- Switched from constant voltage to constant current

- For the cathode, used a piece of aluminum of the same alloy as the piece I anodized. Yesterday, I used a cheap piece of aluminum angle from Home Depot

- Left the dye at room temperature. I read that heating may have caused premature sealing keeping the dye from setting.

- Used a different dye on the second piece.

The results are noticeably better. Here is the piece from yesterday with the other pieces. You can see the dyes I used sitting behind them.

http://i12.photobucket.com/albums/a228/mditomo/th_C0CD89D5-07B8-4EB2-A148-4C7E554E847D_zpskalu41ge.jpg (http://s12.photobucket.com/user/mditomo/media/C0CD89D5-07B8-4EB2-A148-4C7E554E847D_zpskalu41ge.jpg.html)

With the new process I got two separate results from the 2 dyes. The Dye More produced a bluish gray and was extremely splotchy. I did remove the piece half way through and wiped it with a paper towel. This may have had an affect. The regular Rit Dye produced a reddish-purplish gray and is much more evenly distributed. I'm interested to see what the real anodizing dye does.

http://i12.photobucket.com/albums/a228/mditomo/th_78C2AF7C-7452-47E9-A0AE-CFFABE3BC967_zpsd1qsskla.jpg (http://s12.photobucket.com/user/mditomo/media/78C2AF7C-7452-47E9-A0AE-CFFABE3BC967_zpsd1qsskla.jpg.html)

Here's a close up of the piece done with the regular Rit Dye. And the two new pieces next to an untreated piece.

http://i12.photobucket.com/albums/a228/mditomo/th_272A4768-7AD1-4462-B550-96D47A790A8B_zpsqqqhycs7.jpg (http://s12.photobucket.com/user/mditomo/media/272A4768-7AD1-4462-B550-96D47A790A8B_zpsqqqhycs7.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_1900040B-A1DD-4AF1-B3FC-0D1B384E988C_zpss9npwuzn.jpg (http://s12.photobucket.com/user/mditomo/media/1900040B-A1DD-4AF1-B3FC-0D1B384E988C_zpss9npwuzn.jpg.html)

As for surface strength and scuff/scratch resistance, I can say that the anodizing produces a great protective layer. Below I've highlighted areas I heavily scuffed with equal pressure and passes on an untreated piece and an anodized piece. You can see the untreated piece is badly marred, while the mark on the anodized piece is barely noticeable even in a flash photo. If you look close enough you'll see a slightly darker line.

http://i12.photobucket.com/albums/a228/mditomo/th_87BEF31C-709A-4FA7-8650-82603189DD0B_zpshveukgq8.jpg (http://s12.photobucket.com/user/mditomo/media/87BEF31C-709A-4FA7-8650-82603189DD0B_zpshveukgq8.jpg.html)

The anodized pieces have a really nice satiny feel to them and don't really show fingerprints. You can even polish it.

I'm considering doing a tut on anodizing once I've tested the other dye and have refined the method. We will see.

[darth_chasm]

HAH SWEET SUCCESS!

Keeping this short. Pro anodizing dye came in and I went at it tonight.

Things done different from last test:

Sanded, cleaned with electric toothbrush, NO acetone.

Freshened my anodize solution.

Heated dye to 140 degrees per instructions.

Anodized for 90 minutes as opposed to 60 minutes.

Upped my amperage per square foot from 5 to 6.

Used pro dye.

Results and couple useless shots of the piece in the dye:

http://i12.photobucket.com/albums/a228/mditomo/th_5476F1FF-C374-44DF-919F-ED64CCD6B28E_zps8oziemfc.jpg (http://s12.photobucket.com/user/mditomo/media/5476F1FF-C374-44DF-919F-ED64CCD6B28E_zps8oziemfc.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_931D1F49-9F98-4A01-B7E3-AA6A3B742108_zpsoboxfcff.jpg (http://s12.photobucket.com/user/mditomo/media/931D1F49-9F98-4A01-B7E3-AA6A3B742108_zpsoboxfcff.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_576B89D3-F672-4FFE-96BD-ED1B96ABF460_zpsl5mav2nn.jpg (http://s12.photobucket.com/user/mditomo/media/576B89D3-F672-4FFE-96BD-ED1B96ABF460_zpsl5mav2nn.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_BA567ACA-20BE-47DA-BA41-B3925B09F65D_zpsfenxaiax.jpg (http://s12.photobucket.com/user/mditomo/media/BA567ACA-20BE-47DA-BA41-B3925B09F65D_zpsfenxaiax.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_8B950727-0485-43F9-AEDB-69BB5DA0C07E_zps4mquuafy.jpg (http://s12.photobucket.com/user/mditomo/media/8B950727-0485-43F9-AEDB-69BB5DA0C07E_zps4mquuafy.jpg.html)

I'm going to do one more test with the exact conditions and materials I have planned for the actual saber parts. If all goes well, I be anodizin!

[Silver Serpent]

Very nice job. When you're done, don't forget to dispose of your chemicals in an environmentally sound manner.

(Seriously, don't just pour that stuff down the drain.)

The anodizing dye did a much better looking job. Very dark.

[darth_chasm]

Very nice job. When you're done, don't forget to dispose of your chemicals in an environmentally sound manner.

(Seriously, don't just pour that stuff down the drain.)

The anodizing dye did a much better looking job. Very dark.


Thanks. Absolutely! I am definitely going to call waste management when I'm done with it.

[darth_chasm]

99.8% of the way there. I still have some minor cosmetic things left and of course the electronics install.

Here she is so far. All etched and anodized.

http://i12.photobucket.com/albums/a228/mditomo/th_8BF0EBDD-2B38-433F-AB6D-CE297CFDF8C7_zps3lybjzwc.jpg (http://s12.photobucket.com/user/mditomo/media/8BF0EBDD-2B38-433F-AB6D-CE297CFDF8C7_zps3lybjzwc.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_D8338FE6-E9A7-4C2A-BD45-E29BEA17FBC0_zpscavumt4o.jpg (http://s12.photobucket.com/user/mditomo/media/D8338FE6-E9A7-4C2A-BD45-E29BEA17FBC0_zpscavumt4o.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_BCA1A37B-1387-4DC8-B7C8-3B3EA3C91358_zpsjeau6d70.jpg (http://s12.photobucket.com/user/mditomo/media/BCA1A37B-1387-4DC8-B7C8-3B3EA3C91358_zpsjeau6d70.jpg.html)

I added a SW inspired thumb grip on the sliding plate and some dots denoting power (one dot) and Aux (two dots).

http://i12.photobucket.com/albums/a228/mditomo/th_11753797-E650-45D9-9AF9-B912E36CE7E8_zpsp6j1f4in.jpg (http://s12.photobucket.com/user/mditomo/media/11753797-E650-45D9-9AF9-B912E36CE7E8_zpsp6j1f4in.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_D3C7953D-6193-4640-BB1E-A099E2F4992B_zpsm6jxzu4f.jpg (http://s12.photobucket.com/user/mditomo/media/D3C7953D-6193-4640-BB1E-A099E2F4992B_zpsm6jxzu4f.jpg.html)

I think I am going to color this circuitry copper.

http://i12.photobucket.com/albums/a228/mditomo/th_A97B9D24-399B-4700-8E2D-6750603F9578_zpsnwckt5mx.jpg (http://s12.photobucket.com/user/mditomo/media/A97B9D24-399B-4700-8E2D-6750603F9578_zpsnwckt5mx.jpg.html) http://i12.photobucket.com/albums/a228/mditomo/th_97F18827-89F1-4EBF-BBC8-3210BFC9E3B5_zps9syfthsw.jpg (http://s12.photobucket.com/user/mditomo/media/97F18827-89F1-4EBF-BBC8-3210BFC9E3B5_zps9syfthsw.jpg.html)

I'll get some proper pictures taken once its 100% done.

[Greenie]

Sweeeeeet! Lookin' good Chasm. I like the etched 'imperial lighting' pattern !i!i!i. Subtle :cool:
Oh, and well done on the bar graph slot. It looks machined

[darth_chasm]

Sweeeeeet! Lookin' good Chasm. I like the etched 'imperial lighting' pattern !i!i!i. Subtle :cool:
Oh, and well done on the bar graph slot. It looks machined

Thank you sir.

CEX is en route!! I'll finish up this post with some pics of the install and then post some pics of the color-y goodness over in the gallery.

So excited to button this one up. It's been a long road.

[darth_chasm]

OK, she's all wired up and running great. Still familiarizing myself with R.I.C.E. and all the configuration settings but it's coming along nicely.

Here's a top view of everything. I wasn't able to get everything wired under the board with my internal configuration so some things had to go on top.

http://i12.photobucket.com/albums/a228/mditomo/th_IMGP0174_zpsholan3hq.png (http://s12.photobucket.com/user/mditomo/media/IMGP0174_zpsholan3hq.png.html)

Underneath. Don't mind the dirty nails I was workin hard :)

I modified the chassis disks so I could flip up the board for SD card access. It snaps back in and is a tight fit.

http://i12.photobucket.com/albums/a228/mditomo/th_IMGP0178_zpsvm3ynxtl.png (http://s12.photobucket.com/user/mditomo/media/IMGP0178_zpsvm3ynxtl.png.html)

Stuff 10 wires through two tiny holes and snake them through more holes? Sure, no problem.

http://i12.photobucket.com/albums/a228/mditomo/th_IMGP0175_zps1a08beo1.png (http://s12.photobucket.com/user/mditomo/media/IMGP0175_zps1a08beo1.png.html)

I'm not overly thrilled with how my crystal red led is mixing. I may change it out sometime down the road.

http://i12.photobucket.com/albums/a228/mditomo/th_IMGP0181_zpsh0d5scue.png (http://s12.photobucket.com/user/mditomo/media/IMGP0181_zpsh0d5scue.png.html)

But blue and green look great!

http://i12.photobucket.com/albums/a228/mditomo/th_IMGP0182_zpsnmv7cvjg.png (http://s12.photobucket.com/user/mditomo/media/IMGP0182_zpsnmv7cvjg.png.html) http://i12.photobucket.com/albums/a228/mditomo/th_IMGP0183_zpskkqpb2pq.png (http://s12.photobucket.com/user/mditomo/media/IMGP0183_zpskkqpb2pq.png.html)

I'll get some glams up in the gallery soon.

[Generic Jedi]

Great job on the wiring and cram-fu! Those modified acrylic discs are awsome!