LED hilt tutorial

[Strydur]

NOTE: This tutorial is way out of date and is being kept only for posterity's sake. Tim no longer carries this kit. Look in this board for newer tutorials.
http://forums.thecustomsabershop.com/forumdisplay.php?f=26

~LM

This tutorial will show you how to build a basic LED hilt using my LED hilt kit.

http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/1.jpg
LED hilt kit (wrong resistor show)
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/2.jpg
First you need to drill some mouting holes and a set screw hole in your blade holder. I use two 8-32 mounting and one 10-32 thumb screw.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/3.jpg
Cut your tube down to size. Make sure you leave enough room for all of the electronics.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/4.jpg
Drill holes in the hilt that match the holes you put in to blade holder. A paper template works great for this.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/5.jpg
Drill a hole for your switch making sure the blade holder will not be in the way of where you place the switch.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/6.jpg
Mount the LED to the heatsink portion of the blade holder. Make sure you mount it exactly as shown or the lens holder will not mount correctly.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/7.jpg
Solder some leads to the LED.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/8.jpg
Mount the lens holder.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/9.jpg
Mount the lens onto the lens holder.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/10.jpg
Slide the blade holder onto the led assembly.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/11.jpg
Install the mounting screws.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/12.jpg
Now its time to wire everything up.
Negative goes from battery connector to LED.
Positive goes from battery connector to switch then resistor then LED.
To determine which resistor you need for your LED, check out our resistor chart (http://www.thecustomsabershop.com/t-resistors.aspx).
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/13.jpg
Here is the wiring all heat shrinked and then electical taped.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/14.jpg
Good time to test that everything works.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/15.jpg
Slide it all together and install the screws and the switch nut.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/16.jpg
Install the batteries and the end cap.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/17.jpg
Lighted with lights on.
http://www.thecustomsabershop.com/sabers/scripts/ledtutorial/18.jpg
With lights off.