Greyflex Build Log

[Darth Nurse]

Well, quite a few parts arrived today for my Graflex inspired build that I am calling Greyflex.

BH 20
TCSS Glass Eye
4" extension with cutouts for switch box #2.
Double male extension
Prizm
Various chassis and CC parts
Battery (not pictured)

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I still need quite a few CC and chassis parts, handle, pommel, Kobold D ring, switches and a few other odds and ends.

[Darth Nurse]

Made final crustal selection. I am limited in space, so my entire CC has to be 1". This is perfect. I really like the inclusions here. Makes it look tainted.

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zps4si4jwyc.jpeg

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsbzcav1zr.jpeg

[NanoRex]

It's good to see someone else is using faucet seats for crystal holders :) I like the dirty crystal. Usually they light up quite well.

[Darth Nurse]

It's good to see someone else is using faucet seats for crystal holders :) I like the dirty crystal. Usually they light up quite well.

I bought two different sizes. I will need to get the oddball taps for them so I can drill and tap the aluminum chassis disc.

These seem perfect for mounting the accent LED.

[Darth Nurse]

Got some brass pipe in today that may do well for the reveal chassis design. Fits perfect in the MHS parts.

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsqwutmlbo.jpeg

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpss0pxkmyn.jpeg

[Darth Nurse]

Looking at the feasibility of mounting the battery underneath the switch box.

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsatqz7qmk.jpeg

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpshnz1tzkl.jpeg

I think the monentary switches are not going to be an issue, but the recharge port may be???

[CET]

The recharge port will definitely be a problem. You could mount the recharge port in the pommel.

[Darth Nurse]

The recharge port will definitely be a problem. You could mount the recharge port in the pommel.

Issue there is that I want to do a full reveal and just be able to unscrew the handle/pommel. If I am able to relocate the battery, there will plenty of room to put the recharge port in the chassis, I will then just have to figure out a good way to put the kill key in and still be able to reattach the handle.

[NanoRex]

You can also trim down the legs on the recharge port to allow it to fit on top of the battery (assuming it's also going in the switch box).

[Darth Nurse]

You can also trim down the legs on the recharge port to allow it to fit on top of the battery (assuming it's also going in the switch box).

That is a good idea. Bend or trim them. Same with the aux switch.

If I can move the battery here, it opens up for a more elaborate CC.

[Greenie]

You can solder wires the opposite way to help with the cram- fu. :mrgreen:


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[Darth Nurse]

You can solder wires the opposite way to help with the cram- fu. :mrgreen:


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Fantastic idea!

[Greenie]

Thanks DN. It also avoids any stress on the joints :idea::mrgreen:

[Darth Nurse]

Ordered up some interesting brass beads from Etsy today. Will just need restock on the metal chassis discs...

[CET]

Ordered up some interesting brass beads from Etsy today. Will just need restock on the metal chassis discs...

To quote 4Chan, "Pics or it didn't happen."

[Darth Nurse]

To quote 4Chan, "Pics or it didn't happen."

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Boom.

[CET]

That could be fun. Looking forward to seeing what you do with them.

[Darth Nurse]

Got some 1.25 OD brass washers that I will attemp to drill and cut for CC cooling fins.

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsjowibmif.jpeg

[NanoRex]

Looks like our crystal chambers will be very similar! May I ask how you enlarged the inside of the fitting for the crystal? Mine needs to be a bit larger as well, so I'm thinking of boring out the inside a little bit.

[CET]

Got some 1.25 OD brass washers that I will attemp to drill and cut for CC cooling fins.

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsjowibmif.jpeg

Those look great, where did you get them?

What do you call the things that are capping the crystal?

[Darth Nurse]

Looks like our crystal chambers will be very similar! May I ask how you enlarged the inside of the fitting for the crystal? Mine needs to be a bit larger as well, so I'm thinking of boring out the inside a little bit.

I have not bored anything out yet.

[Darth Nurse]

Those look great, where did you get them?

What do you call the things that are capping the crystal?

They are faucet parts from Home Depot.

[Darth Nurse]

Need. Chassis. Disc. #2 & #4...

[NanoRex]

I have not bored anything out yet.

Whoops, forgot you're using a double terminated crystal. It looked to me like you had a crystal that was going right through it.

[Darth Nurse]

Another slow progress update while I wait for a chassis disc restock...

Test fitting some brass beads on the chassis rods. The round ones fit great, the flatter are a tiny bit small so will need some work.

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpszft5izdp.jpeg

[Darth Nurse]

Hmm... What can I do with this...

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsqlclgqna.jpeg

[Darth Nurse]

Here is how much room we have with the battery under the switches.

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsakq2cxol.jpeg

[CET]

You could always trim the switch legs to make more room.

[Darth Nurse]

You could always trim the switch legs to make more room.

The plan is to trim and/or bend them.

Placing the battery here will free up a ton of room for a reveal chassis.

[CET]

Hope it works! :D

[Greenie]

Trim them by half and solder your wires sideways

[Darth Nurse]

Trim them by half and solder your wires sideways

I think that will be the plan.

My actual biggest nemesis here will be the LED resistors. I need to make sure they are small. I have a non-lit switch on standby if I need to eliminate a wire and a resistor to help things fit. I plan to light the CC from the bottom for sure (maybe top too if I have room).

[NanoRex]

If you plan on using the accent pads for the LEDs, then use the little SMD resistors that go on the board. Zero extra space taken up :)

[Darth Nurse]

If you plan on using the accent pads for the LEDs, then use the little SMD resistors that go on the board. Zero extra space taken up :)

Good call. I am still deciding how I will run the CC LED.

[Greenie]

Don't forget you can put a resistor at any point between A and B, even routing the wire where there may be a little more space to fit ;)

[Darth Nurse]

As I wait for chassis discs...

I am considering doing a leather wrap handle that will be aged appropriately for the weathering. I would use trim rings and a 4" extension. That may add a very different touch to a Graflex inspired build.

[Darth Nurse]

Progress!!

Started the CC. Had to drill and tap the chassis discs. I really did not have the best tools for this but made do.

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Still a ton of work to do, but not a bad start. This will be a small CC (<1") so need to look a creative ways to make it cool.

[NanoRex]

Great start! Looking forward to seeing more progress.

[CET]

Lots of holes for lots of greeblies!

[Darth Nurse]

Lots of holes for lots of greeblies!

And wire pass through.

[Darth Nurse]

Working on layout of the chassis.

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[Darth Nurse]

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Things are starting to come together...

[Cire Yeldarb]

Liking that chamber!

[SPACEMONKEY1]

Looks awesome DN!!

[TheSilverDark]

Looking good so far!

[Darth Nurse]

Ordered parts to start up on this project again. I can at least finish the chassis and get things wired while waiting for extensions and pommels to come back in stock.

[rumlyne]

Very nice build so far! Can't wait for your parts to arrive!

[girot]

Loving your progress on this. THANK YOU for posting the pic of that brass pipe. i hopped on Amazon the second I saw the info on the sticker. so, the normal MHSv1 disks fit inside the pipe, you say?

[Darth Nurse]

Loving your progress on this. THANK YOU for posting the pic of that brass pipe. i hopped on Amazon the second I saw the info on the sticker. so, the normal MHSv1 disks fit inside the pipe, you say?

Not inside, they are the same diameter as a normal chassis disc so the pipe can be used as spacer once you channel out a bit on the inside for the 4-40 rod. I have not been able to find anything metal that can sleeve the chassis discs but still fit in the hilt.

[FenixFire]

Not inside, they are the same diameter as a normal chassis disc so the pipe can be used as spacer once you channel out a bit on the inside for the 4-40 rod. I have not been able to find anything metal that can sleeve the chassis discs but still fit in the hilt.

What about .040 wall brass pipe. Various online outlets have 1.25"x 0.040 wall seamless brass tube. Should have about a 1.17" ID, so you would have to use the 1.15" disks for the "ribbed" MHS parts or see if Tim could laser out some custom ones.

[Darth Nurse]

What about .040 wall brass pipe. Various online outlets have 1.25"x 0.040 wall seamless brass tube. Should have about a 1.17" ID, so you would have to use the 1.15" disks for the "ribbed" MHS parts or see if Tim could laser out some custom ones.

Have not thought of that. The pipe I have now is a bit thicker. Can you PM me where you saw the thinner pipe?

[FenixFire]

Have not thought of that. The pipe I have now is a bit thicker. Can you PM me where you saw the thinner pipe?

in your box. I typically get mine from a local retailer/salvage/fabrication yard that sells scrap/cuts by the lbs. My sons sabers are even on their website and for a split second on the TV ad between images of some cool rat rods.

The .040 should allow the rods to pass through with very minimal filing at the ends.

[Darth Nurse]

I ordered the thinner pipe. There not a ribbed section disc for the Prism, but I still may be able to work something out and at least more easily use the pipe as my spacers to make a solid chassis to cover all the wiring and board.

[Darth Nurse]

Looks like I will have 9 wires to pass through the crystal chamber. Most will be 28g, but I will likely go 26 for my main power wires from the recharge port.

Very rough mock-up.

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[Darth Nurse]

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Thinner brass tube arrived, so now playing with using it as a spacer. Will prolly drill holes or slots and back with screening and put an accent LED in there.

[rumlyne]

Looks very promising!

[Darth Nurse]

Next iteration:

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpskoaubiht.jpeg

[Darth Nurse]

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsm7zocq4h.jpeg

[Darth Nurse]

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsxrd7qqb4.jpeg

[Darth Nurse]

Trying out screen inserts for ventilation.

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsdklbevwk.jpeg

[Darth Nurse]

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsrd2yisim.jpeg

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zpsyzimobnq.jpeg

[NaasadTal]

Beautiful!

[Kreyhn]

I know you probably don't need someone else telling you this, but your chassis is coming along incredibly. I really like your design!

[alcadude]

Just magnificent.

[Darth Nurse]

A little pre weathering work on BH 20...

http://img.photobucket.com/albums/v280/jinx667/Mobile%20Uploads/image_zps0wt4nuri.jpeg

[Tal'rin Oz]

Any updates on this thread? This looks amazing!