Advice on using plastic ABS waste pipe in saber construction

[Bescherman]

Hi all. I've been lurking for a year (posting here and there) but haven't yet actually built a saber yet. I usually jump in at the deep end with these things, buy loads of expensive tools then get distracted with something else! As a result I'm starting small and simple.

Inspired by Ultra's Padawan sabers I'm looking into using Plastic ABS waste pipe as the basis of a hilt to build a saber. The idea is to play around with cheap and easy to manipulate material at first. I'd also like to build a couple of Padawan sabers for my cousin's small kids. Also, I'm in the UK and can't easily get hold of things like sink tubes so I'm working with what I can get my hands on.

I'm pretty up to speed on the whole theory of construction and the electronics etc. What I want is some advice from people who have used plastic tubing as a basis for hilts. This (http://www.diyland.co.uk/modules/catalog/product.asp?prod_id=3323) is the kind of stuff I have.

I have 32mm (1.260 Inches) and 40mm (1.575 Inches) OD widths. Both are about 2mm thick. I have the following questions (and would welcome any other advice anyone has from their own experience):

1) Will a blade set screw strip the thread? If so I'm planning to put a ring or layer to drill and tap through as well, maybe the same plastic or something else (depends what I can find).

2) Am I likely to have trouble with a properly heatsinked LuxIII melting the plastic?

3) Will I need to heat sink a Star0 at all (considering it for kids sabers)?

4) Do you have and recommendations for paint that will not chip or peel (I have seen some threads on this but welcome any pointers you may have. I KNOW I have to clean it properly to get all the release agent off).


I think that's it for the moment. As I said, I'm going cheap and simple to start with! Any input appreciated as I haven't found many relevant topics whilst searching.

Cheers, B

[Darth Lars]

2) Am I likely to have trouble with a properly heatsinked LuxIII melting the plastic?
It depends. I think you should consider that you would have to attach the LED assembly to the tube somehow. ABS is a somewhat flexible thermoplastic and can be bent out of shape even with heat below its melting temperature.


4) Do you have and recommendations for paint that will not chip or peel (I have seen some threads on this but welcome any pointers you may have. I KNOW I have to clean it properly to get all the release agent off).
You could ask around what people in the UK use on armor and helmets. These are usually made of ABS or "styrene" (styrene is a component in ABS).

[Bescherman]

Cheers for that! Both very helpful comments! I might have to do some experimentation with a heat gun to see how hot it has to be to deform! :twisted:

I suspect that if no-one has any direct experience then I'm gonna have to suck it and see... then watch as my carefully constructed hilt withers under the heat of Lux power!

[Angelus Lupus]

Good luck with that, Bescherman, and remember to keep us UK saber fans up to date with hilt alternatives. After all, you're not the only one that's been looking in vain for those sink tubes!

[Bescherman]

I did find 35mm OD (1.378") copper tubing at about £7.50 per metre before VAT. However it comes in 3m lengths so you're looking at about £30 for a length! When I get sufficiend funds together I'm going to order in MHS parts for make a personal saber and play around with more configurations. I also want the parts for a staff but all things in good time! ;)

Edit: I don't know if it was coincidence but I now see Jay-gon's thread HERE (http://www.thecustomsabershop.com/forum/viewtopic.php?t=3529)!

They're PVC as opposed to ABS (although I don't know what the difference is in practical terms) but it looks like I might have found my source of knowledge!

[Barmic Rin]

Well, i've only found one place to get copper for that sort of price. Gonna check another one hopefully this weekend.

make sure you post any results on the PVC pipes!

[Bescherman]

I've found 32mm rubber ferrules (rubber feet that go on the bottom of walking frames, chairs etc) HERE (http://www.meadex.co.uk/acatalog/Type_D.html).
http://www.meadex.co.uk/acatalog/D_washer_sm.jpg
They would make good end caps for a kids' saber... but you do have to order 50!!! Maybe if others in the UK are interested then we could split an order, or I could sell them on once I have 50.

For blade supplies then I'll be looking to Plecter labs. Although in the kids' saber I might want thin walled which erv doesn't do (he does do chrome tubing in 30mm and 35mm though, which is useful for metal saber building).

I've also sent an enquiry off to Armitage shanks for Millennia Traditional Handwheels (part #63714XXCP), which is the plastic equivalent onf the Obi Wan pommel (CLICKY and scroll down).
http://www.partsofsw.com/images/AShwheel.jpg.

That's my progress so far in both the plastic and metal saber lines of research. (http://www.partsofsw.com/bensab.htm)

[Proximal]

Before you buy the abs or pvc, see if you can find an MSDS or a data sheet for the particular resin and look at the melt index. Most polymers are tested at 220 degrees celcius or 190 (if it is an ethylene or olefin). If it is a high melt it will be more grams/10 minutes. If it is a low melt it will have around 8 and under. If it is under 1 gram it is considered a frac melt. You want to find the lowest melt material possible.

Or you could do what I would do and just field test both. *shrug*