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Jay-gon Jinn
08-19-2007, 09:43 AM
Well, I had some extra saber parts lying around on the workbench and decided to put together another one. This is what I'll be using:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-1.jpg

I have a style 1 blade holder, two of the 1.5 inch sink pipe adaptors, a 6" piece of 1.25 inch sink pipe, a 1.5 inch tailpiece extension, with nut and washer, a 1.5 inch sink pipe extension, 12 1.25 inch white poly washers, a 10deg lens, a blue Luxeon III led with a heatsink, and an MR Vader sound board with a speaker (the old $2 speaker), and a 4 AA battery holder from Radio Shack.

This particular board didn't have a clash sensor when I got it, so I "borrowed" one from and old Hasbro Qui-gon Jinn saber that I had lying on the bench and wired it in plac of the missing MR sensor. I then hot-glued it to the board:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-2.jpg

The first thing I did was cut the two pieces of pipe, the 1.25 and 1.5 inch extensios to the desired length, and in the case of the 1.5 inch piece, to the dsired angle. I went with 30 degreres on this one. (Sorry, no pics of that this time!)
I then did a trial assembly:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-3.jpg

This gave me an idea as to how long it will be and where the electronics will sit inside.

The angled hood/shroud turned out pretty nice!
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-4.jpg

The forward grips:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-5.jpg
There are 12 of the poly washers on there, and it really has a nice feel to it. I slid those over the 1.25 inch pipe and sandwiched them with the two 1.5 inch sink tube adaptors.
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-7.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-9.jpg
Using the holes in the adaptors as guides, I drilled the mounting holes in the 1.25 sink tube.

This is the rpommel end of this saber:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-6.jpg

This is where it sits now:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-10.jpg

I drilled and tapped extra mounting screw holes in the top and bottom of both the rear grip and the emitter hood and assembled it. here's a close shot of the emitter end so far:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-11.jpg

So now I just need to drill for the switch, the blade thumbscrew, and add some scoring lines for details. Stay tuned....! ;D

Jay-gon Jinn
08-19-2007, 09:49 AM
Here's what I did to make the forward grip section:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-12.jpg

What I did was put the washers on in opposing directions to simulate a ribbed grip. I thought about maybe using some black ones for this if I can find some, but I kinda like the "pearlescent" look they're getting from the chrome pipe inside them. I got this idea when Novastar said that while he was building his "Flange" saber, that the 1.25 sink tube fits inside the 1.5 sink tube adaptor sold by TCSS. The washers are slid onto the 1.25 inch pipe, then it is slid into the adaptor, which is slid into the 1.5 inch pipe, creating the simulated ribbed grip section.

Jay-gon Jinn
08-19-2007, 09:50 AM
I got the washers at my local hardware store...$.49 each.

Just to better illustrate how this is going together:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-13.jpg

Jay-gon Jinn
08-19-2007, 09:53 AM
I drilled for the switch:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-14.jpg

I then cleaned up the hole and slighly countersunk the hole with a larger bit:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-15.jpg

I put it together, popped in my TCSS thick-walled double-wrap Corbin film blade and took a pic:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-16.jpg

Then I decided to take it apart to add some detail scoring lines to the handle, and maybe mess with the clash sensor, when the board stopped working. I got out the multi-meter and didn't have power to the board. After checking all the solder joints in the wire, I checked the red positive at the board and it had broken off, despite being covered with hot glue. So I re-soldered it and all is fine....except for that clash sensor....the Hasbro doesn't want to register a clas on impact...it'll do it instead when swinging the saber, and it doesn't seem to stop once it starts...it's wierd. I guess I'll have to get a hold of something else for that.

Jedi-Loreen
08-19-2007, 09:54 AM
Looking good so far, Jay. :) Are you going to paint the poly washers, or leave them as is?


Whoa, you posted more since while I was writing my little post. Guess my question is answered.

And you finished it!

Jay-gon Jinn
08-19-2007, 09:56 AM
Thanks, Loreen! I think I'll leave them for now...I kinda like the "pearlescent" look they get from the chrome pipe inside them.

Er Dan Gill
08-19-2007, 10:00 AM
Thats looking pretty slick Jay Gonn. Are you going to be adding anything for grips, or are you going to score the tubing like on your brass hardware saber?

Jay-gon Jinn
08-19-2007, 10:02 AM
need to decide on what to do for grips...should I put lines on the tube like I di on my brass saber, or make some neoprene grips like I did on my son's saber? (I had to replace the craft foam grips that came on that as they were deteriorating badly from handling the saber.)

For reference:
neoprene grips:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Arons%20training%20saber%20sound%20mods/arons-training-saber-24.jpg

Scoring lines:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Polished%20Brass%20MHS%20and%20Sinktube%20Sab er/Brass_MHS_saber_12.jpg

Suggestions, anyone? :)

vortextwist
08-19-2007, 10:10 AM
what did you use to hold the speaker on?

Er Dan Gill
08-19-2007, 10:18 AM
Maybe do both. Instead of going length wise with the neoprene, cut it to a width of about a half an inch and go around the tube with score lines 1/16th" to 1/8th" from the edge of the neoprene. I'd do that with four or five grip sections, depending on how much spacing is needed.

xwingband
08-19-2007, 10:43 AM
I believe he used double sided tape to hold on the speaker. I've done it a few times and I love the exterior strength variety of the stuff.

Something I haven't seen that would be a variation what you've done would be to sand the tube. Then you can get an alternating polished vs. sanded look.

Another idea: Use the foam but cut it in LONG strips. Cut it at a 45 degree angle at one end then spiral it around the area. Repeat and cover the whole bottom. I did this once and it was satisfying, different and I haven't had to replace it. The problem with the foam is the edges getting rubbed against so that spiral all around helps it last.

If I had to vote though on what you've previously done... I'd go for the scoring of lines.

Jay-gon Jinn
08-19-2007, 10:51 AM
Okay, I like the ideas so far! I did have the speaker mounted to the back of the battery pack, but the pull wire I installed (to allow me to pull the battery pack back out, it's a tight fit!), wouldn't let the speaker sit flush, so I removed the speaker and the tape. I hot glued the speaker to a 3/4" pvc coupler that I cut in half, and created a resonator. I packed some window-seal foam around it and in fron of it to hold it in place, and hide the white pvc. Pics of that coming shortly!

Jay-gon Jinn
08-19-2007, 11:02 AM
I decided to put a few scoring lines on it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-17.jpg

A couple on the emitter shroud:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-18.jpg
I had one of these that didn't meet up when I was done... :roll:

Around the switch:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-19.jpg
Same thing happened here...one didn't quite match up...

And a couple on the end:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-20.jpg

I may still make some neoprene grips to try out and If I don't like it, I'll take them off and put more lines on it.

Lord Maul
08-19-2007, 11:09 AM
I like the scoring the best jay gon. grips just don't seem like they would "fit" on that saber.

vortextwist
08-19-2007, 11:10 AM
very cool, man!!

Jay-gon Jinn
08-19-2007, 11:17 AM
Vortex, here's what I did to the speaker:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-21.jpg
The speaker is hot glued to the pvc coupler...it fits right into the end of the coupler because there is a step on the inside of the coupler.

I just stuffed a bit of foam in around it to keep it from rattling:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-22.jpg

It fits in there like so:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-23.jpg

And to keep it from being seen through the strainer, I added a larger piece:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-24.jpg

vortextwist
08-19-2007, 11:21 AM
cool.

Jay-gon Jinn
08-19-2007, 11:25 AM
Yeah, it's cool! This is probably the loudest one of my collection!

Jay-gon Jinn
08-19-2007, 12:06 PM
Here's a short vid of the issue with the Hasbro clash sensor:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/th_100_3139.jpg (http://s119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/?action=view&current=100_3139.flv)

It's not the best quality because I had to use the old digital camera, my new one's battery was re-charging, but you get the idea...it registers a clash when you move the saber, not on an impact...I think it's too sensitive or something.

vortextwist
08-19-2007, 12:08 PM
sounds like the clash and swings are backwards :lol:

Jay-gon Jinn
08-19-2007, 12:13 PM
That's almost what it sounds like, but I can't figure out why it would do that. I have it wired up exactly like the Vader tutorial shows.

goldsaberwarrior
08-19-2007, 12:32 PM
Not suggesting anything on your part, but you may want to check the tutorial again and your wiring incase something is messed up, come loose, or if by chance you did accidently put something in the wrong place. Just to be on the safe side.

Lord Maul
08-19-2007, 12:54 PM
jay gon, it might be how you have the clash sensor set in the hilt. on MRs, they "barrel" on it is horizontal in the hilt, while on yours it appears to be vertical. i'm not sure if that's the reason, but it's worth a shot

xwingband
08-19-2007, 01:05 PM
Wait... didn't the qui-gon have the clash sensor on the board? I have that exact sensor and I'm not sure it's the clash... let me check my bag of fried boards to see.

EDIT: I don't see my Qui board in the bag... may have been thrown out. I seem to remember the black one on the board so maybe I'm just imagining things.

Jay-gon Jinn
08-19-2007, 08:51 PM
This is the board:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-2.jpg

The big black thing on the front near the led leads is the clash sensor from the Qui-gon saber. It's located length wise in the hilt, pointing toward the emitter. As I said, it's wired exactly like in the Vader tutorial. I've tried reversing the wires on it, with no improvement, so I don't think it's wired backwards or anything like that. I may have to try soldering the wires to a different part of the sensor where it was soldered to the Hasbro board. I soldered directly to what looked like the solder point for the internal part on the sensors pcb. I may see if I can get a pic to show this better. It's also possible that this sensor is a different type than the spring and metal cylinder that these came with...I wonder if it's a ball-bearing type....the Qui-gon it came from only had a clash sound effect, with no motion activated swing sounds like on the newer versions.

Jay-gon Jinn
08-19-2007, 09:06 PM
This is the Hasbro Qui-gon board that I took the clash sensor from:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/lux_saber_hasbro_board_alone.jpg
I took this pic when I replaced that Hasbro board in my custom saber with a Vader MR.

Here is the same board now:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/hasbro-qg-sb-1.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/hasbro-qg-sb-2.jpg

Jay-gon Jinn
08-19-2007, 10:14 PM
Here's how I soldered the sensor:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-25.jpg

A shot of the back of the sensor:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/2nd-MHS-hardware-saber-26.jpg

Hasid Lafre
08-19-2007, 10:18 PM
I havent the foggyest idea.

GFORCE13
08-19-2007, 10:30 PM
Me either but never the less that is an Awesome Parts Hilt and it sure is loud, also I have used the plastic rings on my first EL's and if you paint them be prepared to constantly touch them up, because it will chip, even with using Plastic Primer, Paint and a Clear Coat. :wink:

Jay-gon Jinn
08-19-2007, 10:55 PM
Thanks Geforce, I'll keep that in mind!

I wanted to be sure I actually had the clash sensor, so I took it off the board:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/hasbro-qg-sensor-1.jpg

And popped the black cover off:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/hasbro-qg-sensor-2.jpg

Definitely a clash sensor....

Hasid Lafre
08-19-2007, 11:47 PM
How many connection points are there on the sensor board?

Jedi-Loreen
08-19-2007, 11:58 PM
Looks like 3 doesn't it? Looks that way to me.

Hasid Lafre
08-20-2007, 02:12 AM
Maybe you got the wrong wires on the wrong set of contacts?

Jay-gon Jinn
08-20-2007, 08:53 AM
There are three there, and two along the bottom where it was soldered to the hasbro pcb. I've tried it using the other solder point, and having taken it apart, I think the problem is with the spring itself. Notice that it's resting on the cylinder? That's always where it goes to after I move it. I can't tell if the spring is too soft or too stiff right now....it works fine if I move the spring myself with the point of a pencil.

Jay-gon Jinn
08-20-2007, 09:05 AM
I think I've got it as good as it will get....the cylinder was slighly bent, allowing permanet contact between it and the spring. It's still a bit too senstitve, though, and a quick jerk will still set it off. Could be used to simulte a blaster block that way, I suppose.

Jay-gon Jinn
08-20-2007, 09:43 AM
Pics and some better video coming up tomorrow!

Jay-gon Jinn
08-20-2007, 09:11 PM
I fixed the sensor by bending the cylinder back where it belonged:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/hasbro-qg-sensor-3.jpg

I also uploaded a short vid to youtube:
hasbro clash sensor test (http://www.youtube.com/watch?v=FzVSuIblQP8)

And another to photobucket:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/th_100_0361.jpg (http://s119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Second%20Chrome%20MHS%20and%20Hardware%20Sabe r/?action=view&current=100_0361.flv)

Hasid Lafre
08-20-2007, 09:20 PM
looken good jay

GFORCE13
08-20-2007, 11:14 PM
Alright it is looking good, the hasbro sensors really seem like they can be a real pain in the neck. :wink:

Firebird21
08-21-2007, 05:23 AM
I would have to say that you installed the motion sensor.


I'm 99% sure this is your clash sensor.

http://www.yankeetoys.org/lee/hasbro-qg-sb-1.jpg


Your symptoms definitely suggest that you've got the motion sensor, clash with motion, very sensitive spring, and that capacitor like thing is what MR uses...

Jay-gon Jinn
08-21-2007, 07:50 AM
Motion sensor? I don't think so....that saber never had motion activated sounds....only played a recorded swing after every other clash sound. What you've got circled there looks more like a capacitor, or a transistor to me....

Firebird21
08-21-2007, 12:03 PM
Well that's a bummer.

I can't see that thing real well in the pics, but it looks simmilar to the one MR uses.


I guess it's a different color...
http://thecustomsa.web133.discountasp.net/forum/05vader/18.jpg
http://www.yankeetoys.org/lee/hasbro-qg-sb-1.jpg

Jonitus
08-21-2007, 01:04 PM
The circled part is a capacitor. You can tell from the silver top being grooved in a cross pattern as well as the printing denoting what capacity it has in microfarads or picofarads

Novastar
08-21-2007, 03:14 PM
The vibration sensor in the photo with Tim's heatsink on the wood background is called a Yusan vibration sensor.

It is not a capacitor like the yellow circled photo.

The thing that Jay did to fix his sensor was to pull the metal "ring" AWAY from the sensor so that it was not constantly triggering a clash.

The spring in the center vibrates, and touches the outer metal "ring". Which completes a circuit, or breaks a circuit, depending on wiring and all that jazz.

Anyhow. It's pretty easy in concept. It's just a switch! A switch that is activated by vibration. 1 or 0, on or off. That's it.

Firebird21
08-21-2007, 05:55 PM
Ok, before this gets more out of hand, I know now that that's a Cap but I wasn't sure before because of the angle of the pic and the symptoms matched my theory, but after pulling up Tim's pic it's rather obvious. And I know how a clash sensor works.

Jay-gon Jinn
08-21-2007, 08:53 PM
Yeah we all pretty much know how they work....but sometimes pictures can be misleading. All in all I think it turned out rather well, after being put together with mostly a few spare parts. I still need to go through everything and figure how much I have into it. I was also trying to see how nice of a saber I could do while spending the least amount of money.

Novastar
08-21-2007, 09:01 PM
I hear ya, Jay! That was what I was trying to do with the Flange sabers.

Granted, Erv's board is 50% of the cost... and the Li-Ion 18650 set is a pretty expensive part as well.

I imagine replacing Erv's board with a cheapo Hasbro for $5 to $10... and using Alkalines (basically a few bucks) would cut the cost of making a "Flange v3" saber to something like $80, maybe less.

Jay-gon Jinn
09-05-2007, 07:28 AM
With the blade and everything else I put into this saber, total cost was around $142.00, not counting the shipping on parts I ordered. That would put it up around $150-160, I think. I tried to get this one in under the $100 mark, but went over by a wide margin....

DACOTA
09-05-2007, 08:17 AM
Thats really cool,good job man.Thats the anakin board right?

Lord Maul
09-05-2007, 08:41 PM
With the blade and everything else I put into this saber, total cost was around $142.00, not counting the shipping on parts I ordered. That would put it up around $150-160, I think. I tried to get this one in under the $100 mark, but went over by a wide margin....

you call that a wide margin? my MHS i was hoping would cost under 300 bucks. it's over 500 right now :shock:

Jay-gon Jinn
09-05-2007, 09:14 PM
Thats really cool,good job man.Thats the anakin board right?
Nope, '05 Vader.

gundamaniac
09-13-2007, 10:06 AM
Whoa. Very cool saber. How do those washers feel? Did you glue them together or are they being held together by pressure from the segments around them?

Jay-gon Jinn
09-13-2007, 09:29 PM
The washers feel like plastic...not sure how else to describe them....and yes, they are held in place by the tight fit on the 1.25" tube, and the fit between the two adaptors.

Hasid Lafre
09-13-2007, 10:02 PM
Whats your plans for the next hilt?

Jay-gon Jinn
09-14-2007, 10:40 PM
I have some pvc kiddie sabers in the works, and a double pvc for myself.