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bambua
12-21-2015, 08:53 AM
After a year or so of lurking and reading and learning I've taken the plunge and ordered what I need for my first saber! I was actually ready to do it a few weeks ago but the Crystal Focus boards were out at the time but now they are back in stock so it's time to start!

This is my basic design:

12607

I planning on adding some more bits once they get back in stock as well as doing some 3d printing / painting for detail work. I did the internal modeling to get my spacing, it's going to be tight but I think I can pull it off. If not I may have to make an extension for it, but only in the 1-1.5 inch range. I'll see once I do a mockup of the parts after they get in, I'm pretty handing with 3d modeling as well as metal lathe/millwork so coming up with a solution should be fun.

Also going to be in it:

CF 7.5
tri cree RGRB
7.4v 18500 pack
recharge port on the pommel
misc chassis parts

I'll post more pictures / plan once the parts start arriving!

- Bambua

Generic Jedi
12-21-2015, 01:03 PM
Good luck with your build, and don't forget the speaker.

bambua
12-21-2015, 01:48 PM
Good luck with your build, and don't forget the speaker.

Thanks, and don't worry it's in there! I just didn't put it in the list hehe.

Darth Nater
12-21-2015, 08:36 PM
Keep in mind the length of your battery solution and where your switch hangs down. And advice up front, if you have a way of using a double 18500/18650 as opposed to a side by side 14500/14650... do it. My 14500 pack is all that will fit in mine due the length restrictions, and its runtime while never stellar has dropped to the point that I need a new pack 3 years later. My kids sabers that run on single 18500 packs last a long time.

bambua
12-21-2015, 11:33 PM
Keep in mind the length of your battery solution and where your switch hangs down. And advice up front, if you have a way of using a double 18500/18650 as opposed to a side by side 14500/14650... do it. My 14500 pack is all that will fit in mine due the length restrictions, and its runtime while never stellar has dropped to the point that I need a new pack 3 years later. My kids sabers that run on single 18500 packs last a long time.
I will definitely keep that in mind as I mock it up. I have a couple extensions coming as well and will see how everything is going to fit. I'm planing on going either 18500 or 18650. I have a couple of each around and can play with the fit.

Thanks!

bambua
12-31-2015, 10:51 AM
That exciting feeling when you know your saber parts are out for delivery, that sad feeling when you remember USPS doesn't show up for another 4 hours. GAH!

bambua
01-03-2016, 07:00 PM
Parts have arrived, dry fit done, tested wiring diagram and activated the board and it all worked! Will post some pictures as I start the final build.

From the dry fit I have a pretty good idea where I am going to have fit issues and where I have room to hide wire/connectors.

The chassis and soldering wire leads are up first wish me luck!

bambua
01-06-2016, 02:26 PM
First couple 3D printed parts are designed and off to be printed, trying it a few different ways and materials to see what works best.

Kill Key:
12906

Plan is to print this in black, and do some metallic weathering so that it fits in with the aluminum on the saber.

Decorative Ring:
12907

Plan on this is to do a couple prints, first in black and just do some edge highlights with metallic to make it look weathered. Second plan is a print without the screws in it but holes, and then put actual screws into them. Should have the prints in about a week to give them a test will post pictures as soon as they arrive along with a test fit of the full saber.

- Bambua

bambua
01-12-2016, 08:41 PM
So while I wait for the 3D printed parts to arrive I started wiring up my components. For each of them I let plenty of extra wire so I can trim it down to size as I fit it all to the chassis and on to the plugs I'm using.

All of the parts:
http://i209.photobucket.com/albums/bb226/rberrill/saber_parts.jpg (http://s209.photobucket.com/user/rberrill/media/saber_parts.jpg.html)

Here is the LED as it's wired, assembled and inserted in the blade holder:
http://i209.photobucket.com/albums/bb226/rberrill/saber_01_led_wired.jpg (http://s209.photobucket.com/user/rberrill/media/saber_01_led_wired.jpg.html)
http://i209.photobucket.com/albums/bb226/rberrill/saber_02_led_heatshrunk.jpg (http://s209.photobucket.com/user/rberrill/media/saber_02_led_heatshrunk.jpg.html)
http://i209.photobucket.com/albums/bb226/rberrill/saber_03_led_assembled.jpg (http://s209.photobucket.com/user/rberrill/media/saber_03_led_assembled.jpg.html)
http://i209.photobucket.com/albums/bb226/rberrill/saber_04_led_inserted.jpg (http://s209.photobucket.com/user/rberrill/media/saber_04_led_inserted.jpg.html)

Here are the switches, LED and speaker wired:
http://i209.photobucket.com/albums/bb226/rberrill/saber_05_switches_led_and_speaker_wired.jpg (http://s209.photobucket.com/user/rberrill/media/saber_05_switches_led_and_speaker_wired.jpg.html)

Next up wiring up the CF and the CEX after test fitting the chassis...

bambua
01-14-2016, 12:18 PM
First off, first round of 3D prints will be here tomorrow, so excited! Second, I spent the morning designing my chassis now that I've mocked everything up. I used the TCSS chassis pieces for some dimensions and to mock it up and came up with this:

This is a top iso shot of it with the Speaker and connection rods through it, it has a spot for the Crystal Focus 7.5 and a CEX with a battery on the bottom:
http://i209.photobucket.com/albums/bb226/rberrill/Saber-Chassis%20with%20Speaker%20and%20Boards.png (http://s209.photobucket.com/user/rberrill/media/Saber-Chassis%20with%20Speaker%20and%20Boards.png.html)

Bottom iso shot with the speaker and connection rods:
http://i209.photobucket.com/albums/bb226/rberrill/Saber-Chassis%20with%20Speaker%20and%20Boards%20Bottom.p ng (http://s209.photobucket.com/user/rberrill/media/Saber-Chassis%20with%20Speaker%20and%20Boards%20Bottom.p ng.html)

Top iso shot without boards or speaker holder:
http://i209.photobucket.com/albums/bb226/rberrill/Screen%20Shot%202016-01-14%20at%201.08.32%20PM.png (http://s209.photobucket.com/user/rberrill/media/Screen%20Shot%202016-01-14%20at%201.08.32%20PM.png.html)

Hopefully this will work out! It's exciting to finally be getting these pieces I've been planning on and see how they are all working together.

- Bambua

darth_chasm
01-14-2016, 12:54 PM
Very cool!

Are you strapping the battery to the chassis with velcro or zip tie? Looks like it might slip out of the channel without.

NanoRex
01-14-2016, 01:19 PM
Very nice! I will likely use some of the design elements of your chassis when I design mine :)

bambua
01-14-2016, 06:20 PM
Very cool!

Are you strapping the battery to the chassis with velcro or zip tie? Looks like it might slip out of the channel without.

I have a couple routes I'm thinking of, I have some nylon webbing about half an inch wide, if I had a couple of those I could put a grommet on them and screw them to the flat part at each side of it. either that or going to go the velcro/doublesided tape route. I'm going to get a couple printed so I have some test room once I finalize the design.

bambua
01-14-2016, 06:21 PM
Very nice! I will likely use some of the design elements of your chassis when I design mine :)

Thanks! Do share your ideas!

bambua
01-19-2016, 12:27 PM
So I realized I had a few issues with the previous chassis design and wanted to fix it before I sent it out to be printed. First issue was I didn't leave enough of an opening to get the SD card out without removing the board, Second thanks to Darth Chasm, didn't even think about the size of my retention on the battery along the bottom, so I pushed it up 1MM and put in a channel to run a tie strap. Questions and Comments welcome!

http://i209.photobucket.com/albums/bb226/rberrill/Lightsaber%20Chassis%20v2%20-%20ISO.png (http://s209.photobucket.com/user/rberrill/media/Lightsaber%20Chassis%20v2%20-%20ISO.png.html)

http://i209.photobucket.com/albums/bb226/rberrill/Lightsaber%20Chassis%20v2%20-%20Bottom%20ISO.png (http://s209.photobucket.com/user/rberrill/media/Lightsaber%20Chassis%20v2%20-%20Bottom%20ISO.png.html)

http://i209.photobucket.com/albums/bb226/rberrill/Lightsaber%20Chassis%20v2%20-%20XRay%20ISO.png (http://s209.photobucket.com/user/rberrill/media/Lightsaber%20Chassis%20v2%20-%20XRay%20ISO.png.html)