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View Full Version : Jay-gon Jinn's third MHS and Sinktube Saber (MR sound w/ III red)



Jay-gon Jinn
01-06-2008, 06:37 PM
I had parts to build another one of these sabers, so since i'm off work for a while, I thought I'd get started! This one will feature the pearlescent front grip, an MHS style 1 blade holder, two MHS sinktube adaptors, about a dozen polywashers,and a chrome 6" sink tube tailpiece extension:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0394.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0395.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0396.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0397.jpg
I have two led's I could use for this one, a red Lux III or a green Lux III. I'll have to order a few more small parts from TCSS in order to finish the wiring on this one. I'm out of the quick disconnect and a few other things, but I have enough parts to put together the main body!

Jay-gon Jinn
01-06-2008, 06:38 PM
The first thing to do is slide the polywashers into place on the 1.25" tube. I used a 20 guage commercial grade for this, so it'll take threads better than the 22 guage type:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0398.jpg
Some of them had to be trimmed with an x-acto knife to remove extra flashing.

Jay-gon Jinn
01-06-2008, 06:40 PM
Next, I assembled the speaker grille using the nut and washer provided with the slip-joint extension:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0399.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0400.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0401.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0403.jpg
A quick and simple speaker grille! The grille is actually a sink strainer I picked up at the hardware store. It looks blue because it still has the protective wrapper on it.

Jay-gon Jinn
01-06-2008, 06:41 PM
The next step was to drill the sinktubes for the adaptors:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0404.jpg
I drilled the first hole using a small bit and drilled it through from the inside. I then switched to the #29 drill bit for the 8-32 threads that I will tap later and drilled the hole through from the outside. Using the hole in the adaptor as a guide, I then continued through to the other side as well.

For the secon set of holes, I measured the distance from the center of the first hole to the center of the second. I markedthe center with my x-acto knife (just a scratch is all it took) then using a center punch, marked the location:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0405.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0406.jpg
The center punch will leave an impression in the tube to prevent the drill bit from "walking." These holes could be done in a drill press as well, but I thought since not everyone has one, I'd just use my cordless drill for these.

Jay-gon Jinn
01-06-2008, 06:42 PM
Again, I started with a small hole to be sure I hit the mark:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0407.jpg
It was pretty close, so I changed the bit out again to the #29, and drilled it through:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0409.jpg
I used the holes in the other side of the adaptor to guide the drill bit so the holes lined right up. Now it's time to drill for the 1.25 inch tube to fit inside the adaptor!

Jay-gon Jinn
01-06-2008, 06:43 PM
I installed the front grip into the adaptor ad drilled through the holes in the adaptor and the 1.5" tube, into one side of the 1.25" pipe:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0410.jpg
Don't try to drill straight through on this step, it may not line up. I then tapped the hole with the 8-32 tap and my tap handle, and installed a screw. this will help hold the 1.25" tube in the adaptor so I can drill and tap the rest of the holes.
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0412.jpg

Jay-gon Jinn
01-06-2008, 06:44 PM
I finished drilling and tapping the holes for the center adaptor and put it together:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0414.jpg
Next, I did the front adaptor. This was easier to do, so I didn't take any pics. It will be exposed on this saber, as it came from TCSS with a better finish than the other one. It came out fairly nice:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0415.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0416.jpg
This adaptor was easy to drill and tap for, as it simply slid over the end of the 1.25" grip section. I lined up the drill bit through the threaded holes already present on the adaptor and drilled and tapped them one at a time, inserting a screw each time to ensure the adaptor wouldn't move.

Jay-gon Jinn
01-06-2008, 06:46 PM
Next thing to do is drill for the switch! I'll be using the standard click on/click off push button from TCSS, so I drilled a 3/8" diameter hole in the drill press:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0418.jpg

After that, I put the grip marks on the rear grip and taped it up:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0421.jpg

Jay-gon Jinn
01-06-2008, 06:48 PM
I taped up the ends of the grip area because this hilt is getting the "brushed finish grips":
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0422.jpg

They didn't turn out too bad, either:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0423.jpg
I've done this before on another saber that I haven't posted here yet. I have a wire brush on the bench grinder that I use to make the rough, dull finish on the grips.

Next up is to drill and tap for a CT knob, and decide if it should have the black anodized one or the raw aluminum one.

savyas
01-06-2008, 07:28 PM
thanks for the pics, you've really given me some ideas. So far, I've been concentrated on the electronics aspect of building a saber, putting the hilt on the backburner, mostly because I'm undecided on how to build it. Every pic I've looked at has given me a new idea... and since I'm new at this, I don't want to make my 1st saber too complex.

Are those both 1.5 inch sink tube adapters? From the pics, it looks like one sink tube is 1.25" and the other is 1.5". I like the pearescent grips, BTW.

Jay-gon Jinn
01-06-2008, 08:21 PM
Those are 1.5" sinktube adaptors, and the tubes are also 1.25 and 1.5 inch. The 1.25" tubes fit inside the adaptors, and the adaptors fit inside the 1.5" tubes.

Jay-gon Jinn
01-07-2008, 05:34 PM
So after I finished the brushed rear grips, this is where it stood:

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0425.jpg

Most of the major construction work is done, and it's time for the electronics:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0431.jpg
The soundboard/driver for this will be an MR Vaderboard running a red Lux III. I soldered up all the connection and attached a pull wire to the battery holder:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0433.jpg
I soldered everything except the led, which I'll do last:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0432.jpg

Jay-gon Jinn
01-07-2008, 05:48 PM
The next thing was to cut a resonator for the speaker. I used a simple 3/4" pvc coupler (I cut in half on my mitre saw) for that:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0436.jpg
I was out of quick disconnects for the led, so I just soldered some wires (blue for +, yellow for -) to it and hot glued a lens holder in place:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0435.jpg

Once that was all done, it was time to slide it all into the saber hilt. The only difficult part was installing the switch. It involved a screw driver and careful prodding, but I got it all in there and assembled it for a test:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0440.jpg

Jay-gon Jinn
01-07-2008, 05:58 PM
I wasn't going to do this to this one, but the emitter looked to plain to me...and I happened to have the other half of the shroud from the other saber left over, so I cleaned it up (deburred it) and slipped it on:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0455.jpg

That looked okay, but I wanted to do something a little different on it than I had on the other one, so I scored it and taped it off, then took it to the bench grinder and the wire wheel:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0457.jpg

I like that! Ties it into to the rest of the saber!

Jay-gon Jinn
01-07-2008, 06:06 PM
So now about the last thing to do is drill and tap for a couple of mounting screws for thshroud, and the blade set-screw. I lined them up with the other screws along the sides of the saber, and marked them off. I drilled them on the drill press, and tapped by hand. I did the same with the blade screw, which was for a 10-32 thread. I like the larger screws for the blade, they have more bite. And here's how it came out:

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0462.jpg
Unlike the other saber I built like this, the blade holder can be removed with the shroud attached, as it is screwed only to the blade holder. Unfortunately there is one small error on this one, and it has to do with the switch:

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0461.jpg
It's a little off-center, but I found it works out okay like that. There's a bit more room for my thumb when holding the saber.

Jay-gon Jinn
01-07-2008, 06:13 PM
Well, I think this one is done!

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0465.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0464.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Third%20MHS%20and%20Sinktube%20Saber/000_0458.jpg

It's shown in the above pic with one of my thin-walled Dual-Core Diffuser blades. The sound is pretty good, even though this uses the old $2 speaker from the store. The only thing I'd like to change on it is the nut on the pommel end...it needs a chrome one, or maybe even a polished brass one.

ArkaiHalon
01-07-2008, 08:26 PM
Great looking saber. I like the brushed look of the grip and shroud.

37H4N
01-07-2008, 09:30 PM
Truly awesome Jay-Gon! I've been wanting to make a sinktube saber for a while now but didn't quite know much about how to make one. So I thank you for all the pics, I think they will come in handy when the time comes to make mine!

BhujangiJedi
01-07-2008, 09:54 PM
Really nice saber! Thanks for posting this stuff - this post and others of yours are very nice for those of us who haven't (yet) built a saber. Great pics and description!

DarthFender
01-08-2008, 02:28 AM
Jay,

What's the angle of that shroud cut? Or did you just let the Force guide you?

Jay-gon Jinn
01-08-2008, 07:22 AM
If memory serves, the shroud was cut at 30 degrees.

strengthofrage
01-08-2008, 08:22 AM
This is a great tutorial on building a sink tube MHS saber Jay-Gon, the pictures and descriptions are very detailed. This would be a great 'start to finish' thread.

Great looking saber!

Suman Das
01-08-2008, 10:06 AM
awesome job man. I love the grips. I hear ya on the endcap I hate mine too. Looks ghetto compared to all the bling. But im surwe youll figure something out

Jay-gon Jinn
01-08-2008, 10:42 AM
This is a great tutorial on building a sink tube MHS saber Jay-Gon, the pictures and descriptions are very detailed. This would be a great 'start to finish' thread.

Great looking saber!

That's mostly why I post threads on the sabers I build. It shows you what you can do with the parts in the store and how to do it.

DarthFender
01-13-2008, 08:40 AM
If memory serves, the shroud was cut at 30 degrees.

Thanks, and forgot to say that is a very beautiful saber. Keep up the good work.

xl97
02-12-2008, 11:46 AM
hi..

I jut wanted to clarify here..

for the shroud. did you jus use soe extra 1.5 sink tube that you cut on an angle?

and if fits over the #1 LED emitter/blade holder??

Thanks

Jay-gon Jinn
02-12-2008, 12:52 PM
hi..

I jut wanted to clarify here..

for the shroud. did you jus use soe extra 1.5 sink tube that you cut on an angle?

and if fits over the #1 LED emitter/blade holder??

Thanks

Yup. The blade holder was attached to a 1.5 MHS Sinktube adaptor as well.