Custom Hilt, reveal chassis, cf9 w/ cex build

[Darth Leximus]

This is one of the more involved commissions I've been given the honor of building. The trick to this one will be space management, I like to make all my hilts as slim as possible, most falling just over 1.25" in OD, this makes fitting intricate chassis a challenge. Especially when the client requests a fully loaded CFv9 w/ CEX and no single cell hack....We will see how this goes!

https://i.imgur.com/7UkrLRpl.jpg

Here is the design sketch that was approved by my client, the size is not to scale, but it gives an overall layout of how it will go together.

https://i.imgur.com/lVcubQVl.jpg
https://i.imgur.com/EOQnaYZl.jpg
https://i.imgur.com/EvkZqMal.jpg

I approached this one a bit backwards and started with the shrouds. These will still receive a fair amount of filing and sanding to get everything straight and perfect. They were cut from 1.25" copper tubing using the trusty dremel.

https://i.imgur.com/qcyuijYl.jpg

Found some good cutoff spare pieces of aluminum to use for the main hilt...let the machining commence. I use a Grizzly G0516 Lathe/Mill Combo. Overall the machine works well, its the first heavy machine i've ever purchased, if I had it to do again I would buy the lathe and mill seperately, the lathe is hampered by having the mill attached but I find most milling jobs to be hindered by the limited workspace.

https://i.imgur.com/aJdaFXPl.jpg
https://i.imgur.com/BNdmoY3l.jpg
https://i.imgur.com/o8Oix5Fl.jpg
https://i.imgur.com/3Ta5Bu2l.jpg
https://i.imgur.com/ExOOHnUl.jpg
https://i.imgur.com/h3SIDyEl.jpg

Both halves came out really nice and the shrouds fit perfectly snug without marring the finish of the aluminum. Next will be only my second attempt at threading so fingers crossed I don't ruin these beautiful pieces lol. I will practice on scrap until i have the whole process down.

After the threads are done, I'll be boring out the bottom half a bit more to help accommodate the batter and board being sandwiched to help maintain space. All the main electronics will be housed in the lower half to allow for the top to be an intricate crystal chamber.

Finally the main hilt pieces will have windows milled for the various reveals and finally the chassis work will begin.

Thanks for looking!

[Seth Skywalker]

You've done it again! Really nice design. Excuses me for asking, but how are you going to make the threading?

[Darth Leximus]

You've done it again! Really nice design. Excuses me for asking, but how are you going to make the threading?

The threading will be cut on the lathe

[Tom Tilmon]

I love those copper shrouds! Are you hand cutting them? That's a lot of work. Very nice. PS, this is a distraction from your personal build! I love the layered different metals look.

[Darth Leximus]

I love those copper shrouds! Are you hand cutting them? That's a lot of work. Very nice. PS, this is a distraction from your personal build! I love the layered different metals look.

Thanks! Yes I hand cut all the shrouds. My personal build is a spare time thing, I do about an hour of work on it every couple of days lol. I have 5 full custom commissions and another 5 sabers I'm altering or adding too in one way or another. This is why I don't have a saber of my own, I always feel like I'm stealing time away from other people's builds when I'm working on my own.

[Darth Leximus]

A few more updates on this one. Mill work on hilt and more refinement of the shrouds. Waiting on my hunk of solid brass to make the reveal chassis for this one.

https://i.imgur.com/NT6lqKtl.jpg
https://i.imgur.com/WQ74WnXl.jpg
https://i.imgur.com/RrEnAGfl.jpg
https://i.imgur.com/YrZZPfZl.jpg
https://i.imgur.com/k78R2Njl.jpg
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https://i.imgur.com/eUTZbngl.jpg
https://i.imgur.com/xVv91OQl.jpg
https://i.imgur.com/n4iO7HIl.jpg
https://i.imgur.com/2CeVJ77l.jpg
https://i.imgur.com/QYvspC9l.jpg
https://i.imgur.com/cOvXIGul.jpg
https://i.imgur.com/iABvl5Ml.jpg
https://i.imgur.com/Y5CrN1Il.jpg
https://i.imgur.com/lI3jr2Nl.jpg


More Soon, thanks for looking

[Seth Skywalker]

That copper is just :shock:

[Darth Leximus]

That copper is just :shock:

Thanks, the client wants them highly polished. I'm considering trying to convince him to let me do a little flame treatement to the tip of the emitter first. I want this thing to look as realistic as possible

[Jediseth]

Looking awesome man!

[Darth Leximus]

Looking awesome man!

Thanks man

[BrutalMaz]

Looks amazing so far! Can’t wait to see it finished!

[Darth Leximus]

Thanks very much!

Quick update, the client just changed this from a CF9 to a Prizm with Neopixel....so more room for fun stuff on the reveal!

[Vereous]

I'm a big big fan of copper shrouds, but I've never polished one before. I'll be interested in seeing how these turn out. They're amazing so far.

[Swiftey90]

Do you mind me asking, what material pipes/tubes did you use and what dimensions? Also where did you get them? I have been looking for metal pipes that fit together well for a long time but I still struggle to find without custom fitted stuff which is super expensive. Thankyou

[Darth Leximus]

I started with 1.5" OD x 1" ID 6061 aluminum and 1.25" copper pipe. I machined everything to fit with extremely tight tolerances. I've since threaded the lower half to go one a solid brass inner chassis. I'll be posting updates soon.