Jay Gon's "Agony" (conversion from EL to luxeon)

[Jay-gon Jinn]

Okay, this will continue where this thread (http://forums.thecustomsabershop.com/showthread.php?t=2500) left off.
After having damaged the EL wiring while attempting to upgrade the sabers' switch, I have decided to try to convert this one over to a Luxeon-based saber, and may eventually go so far as to add sound as well.

Since the blade was epoxied into the emiter hole, it was non-removeable. I took care of that with a tubing cutter and my hacksaw:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/100_1761.jpg

There is still a bit of the blade inside the emitter:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/100_1760.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/100_1759.jpg

I'll need to go to the hardware store and get a 3/4" drill to drill out the remaining blade material. So for now, this is what it looks like reassembled:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/100_1756.jpg
It has a black switch from the store temporarily installed to fill the hole...it doesn't quite fit as the hole is too large for it, but it looks a lot better.

[Lord Maul]

I hope this turns out well for ya Jay Gon. Your blade removal method was totally redneck :mrgreen:

[Malaki Skywalker]

Thats a pretty sweet looking saber! Can't wait to see it Luxed up! :D

[Jay-gon Jinn]

I hope this turns out well for ya Jay Gon. Your blade removal method was totally redneck :mrgreen:

I know....purty cool, ain't it? ;)

[strengthofrage]

lol I love this forum :)

That is purty cool... I do like the saber and I definitely like it better minus the original square button. Hope it works out Jay-Gon.

[Hasid Lafre]

I think a skinny and short control box would make that look more intresting

[Jay-gon Jinn]

At one point, I had installed a momentary switch from Radioshack that looked like this:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/el_saber_new_switch.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/el_saber_new_switch-2.jpg

That one looked better, but there was no way to attach it because the retaining nut goes on the bottom of the switch. Right now, I have this switch on it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3313.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3312.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3314.jpg

A slim "switch plate" would be a big plus on this, and might even allow for some different types of switches to be used. I'm not sure if this will be able to house a soundboard or not.

Here's how it breaks down:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3315.jpg
There are three pieces; the forward grip/emitter:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3318.jpg
This is one of the little details I liked...the coin edge knurl on the "lens."
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3316.jpg
This end of the forward grip has what looks like spacer that has been pressed fit into the grip...I'm not sure what it's purpose is, except maybe to strengthen the joint with the switch tube. I'll probably have to drill it out to fit an led mount and lens assembly in there.
Next piece is the switch body tube:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3319.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3320.jpg
This is where everything will have to go, as far as the switch, batteries, and soundboard, should I try to use one in this saber. there is only room for four AAA size batteries in a linear set up in there. A soundboard might fit on top of them if the right kind of switch is used. Then there's the pommel:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3321.jpg
It's a solid chunk of aluminum that really doesn't quite fit with the style of this saber, so a new one may have to be mad for it. I could hollow it out, but I doubt if I'd be able to get much sound out if it anyway; there isn't much room for holes to allow the sound to escape.

With any luck, I should be able to do something with this in the next month or two. I'm still trying to decide what I'm going to do with it, but I think the first thing is to drill out the rest of the blade, and see where I'm at then. (I'm still deciding on what color this should be...I'm thinking amber...or maybe a filtered purple...)

[Hasid Lafre]

I think you should go red-o with a set of pucks.

[Obi-Dar Ke-Gnomie]

I used to have one of those red momentary switches on the first incarnation of my saber. It was a nice switch, but a real PITA to install.

I had to pull the wiring through the switch hole and solder the wires to the switch with the nut on them already inside of the hole. I then had to work from the emitter end with the LED hanging out and try to force the nut to turn with a flat screwdriver. Like I said, PITA.

That's a nice saber. Should be nice when it's done. I know that you can make it work, but I don't know if it's something I would tackle. Good luck, and MTFBWY.

[Jay-gon Jinn]

Well, I picked up my 3/4" drill bit on Friday, and had some time to kill Saturday afternoon, so I popped the forward grip in the drill press:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3325.jpg

I squared it up and made sure it was clamped tight, and after an initial pass, there was still a bit of polyC in there, so I pulled it out with a pair of needle nose pliers:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3328.jpg

I drilled out some the remaining blade and checked to see what was left:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3329.jpg

It looked like I got enough of it to see what was in there so....I got my hammer and punch, and one tap later, this fell out:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3330.jpg
your standard EL blade plug...I knew that's what was in there! It's too bad that Random epoxied the blade in the emitter, this would've been cool with a detachable blade. You can now see daylight on the other end of the grip section:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3331.jpg

There was still some of the blade in there, so I put it back in the drill press and got this cool action shot:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3333.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3334.jpg

I think that got it all out, so now I need to figure out how to get the other half of the plug out. I think I may just drill it....

[Hasid Lafre]

Cant drill it to 1" can you?

[Jay-gon Jinn]

Not unless I want to have the emitter fall off, unfortunately! The neck section under the "lens" is only 1" o.d.
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/101_3318.jpg

I have no problem using thin-wall 3/4" blades, and have had pretty good luck getting them to light up evenly, and brightly.

[Enolmano]

This sure seems to be turning out nice!

And, I do like you methos Jay-Gon...^^

[Vazan Maceu]

Really like that hilt, you´re doing a very good job with it. It´s going to be really beautiful when it gets luxed up ;)

[987654321a]

How are you planning on putting in a luxeon? Are you going for a Star LED? or just the Emmiter? Because the star wont fit in a 3/4" space.

edit- oh and btw that looks awesome haha.

[Jay-gon Jinn]

I'll probably be boring a 7/8" hole the base of the forward grip. That should give me just about enough room for a lens holder and a star led.

[Lord Maul]

Or you could use a Rebel. That's what I'd probably do. They are brighter than a 3 watt and K2

[Jay-gon Jinn]

Or you could use a Rebel. That's what I'd probably do. They are brighter than a 3 watt and K2

If I could find one already mounted to a standard star base, not a moon-style base, I would...I can't work with something that small to try and attach one to a star myself....my fingers won't allow me to handle something that tiny.

[Darth_DevilGuy]

I have a little thing made for working on circuit boards that would make that easier, it has two little alligator clamps and a magnifying glass on a movable framework mounted to a stable metal base. I'll try to find one online for pics, it works wonders for small jobs.

[xwingband]

They're called helping hands... I find the clips helpful but not the magnifier all the time.

Jay-gon, if you want blue I could spare a Rebel. Optics are easily gotten... part 180/120 at future electronics. Here's a pic of the PCB'ed one:

http://www.led-tech.de/images/products/startimage/LT-1136-1189444232.jpg

Epoxy works and the nylon screws I imagine are still possible also. IMO the Rebel in blue is worth it, 48 lumens at 700mA and 3 or so volts. Matches a V at half the voltage.

I need to order more greens if anyone wants to pitch in.

[virus692]

But we are helping we're the helping hands
http://www.retrojunk.com/img/art-images/Helping%20Hands%202.jpg
Flash back anyone?

[Jay-gon Jinn]

Well, it's not that I can't see or hold down what I need to for soldering normally, it's just right now, I went back to work doing a different job, and it's got my fingers, wrists, forearms, elbows, shoulders, and back very sore.

I wasn't planning on using blue, but thanks anyway, X! I have plenty of room now to use any star-based led, as I was originally planning anyway.

I now have to wait on parts, but I can show you what I did yesterday. Now the pics were taken after a bit of frustration...I started out by drilling out the spacer in the end on the grip section with my 3/4" drill bit. This was where the fun began! (Not really, just being sarcastic!) I got down to about 1 1/2", and what was left of the spacer decided to JAM the bit into the grip! I worked for 20 minutes to get it out...and did some damage to the saber's exterior. Oh, well....now it just has the old and used look to it for now. After that, I set up to drill the hilt out for the lens holder. I used my 7/8" bit for that, which looking back now, I probably should've used in the first place:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0009.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0010.jpg

I drilled down about 3/4 of an inch and tested the diameter:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0012.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0011.jpg
Yup, that'll work!

I put the grip section back in the vice and drilled it further. I went over 2" this time. This should give me plenty of room for the optics, led, and a heatsink that I need to have someone machine...I'll llook into that later.

Looking in the grip now, I can see a set screw in there, in the middle of the grip...How did that get in there? I have no clue...but I'd guess this grip/emitter is pressed together somewhere near that screw. It was what was holding the female half of the EL plug in place:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0014.jpg

From the other end:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0013.jpg
This is the emitter end, believe it or not...the face ring came off while I was trying to get the 3/4" drill bit out of the grip...it looks like it was epoxied, and/or pressed into place also. So, then I decided it was time to take a measurement. I loaded in the lens holder, an optic, and a Lux III led I happen to have and took a depth measurement with my calipers:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0015.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0016.jpg
Turns out the length of the heatsink/led mount is going to have to be 1.675". The diameter will need to be .873" to fit inside the .875 hole.

[Jay-gon Jinn]

Well, I just received my custom heatsink, thanks to Lord Technous, a.k.a. Do-Clo. I also have the led I'm going to use so.... Work can now progress on the conversion!

Here's the heatsink:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/100_0204.jpg

I need to do a bit more work to the grip section to get it in there, there's some material in the hole that is preventing it from sliding in all the way, so I ordered a couple of tools from McMaster-Carr.com to fix the problem. I have 3/4" and 7/8" cylinder hones coming.

[Jay-gon Jinn]

Okay, the tools arrived Saturday morning, so I did some work to the saber before heasding into work and took a few pictures as well. I started out by putting the hilt section back in the drill press vise, and honing the heatsink tube out until the heatsink slid in and out fairly easily:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0005.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0006.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0007.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0008.jpg

Time to test fit with the led and lens:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0009-1.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0010-1.jpg

Ahh, sweet perfection! ;D
With that done, I turned it around and did the emitter hole using the 3/4" cylinder hone and got the blade to fit in the socket better as well:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0011-1.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0014-1.jpg
That's a good enough fit, not too tight, but not too loose either. Time to do some soldering next!

[Jay-gon Jinn]

I heated up the iron and soldered leads to the led:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0015-1.jpg

I used the same color coding that comes on the micropuck drivers I used in my PVC hilts; green is negative, orange is positive. I used some heat transfer paste on the bottom of the led. This will help transfer the heat from the led into the heatsink, and is also non-conductive, and should help prevent grounding of the led that reds and red/o's are known for.
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0016-1.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0017.jpg
I don't have enough clearance inside the hilt to use mounting screws, so it will sit on the heatsink like so, and just be held in place by the heatsink after I reassemble the hilt.

I hot-glued the optics holder to the led, and the wires to the channel on the sides of the heatsink. This is using a 10 deg optic because I've found that in my experience with 3/4" blades that they work better with a 3/4" Ultrafilm than a 5 deg.
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0018.jpg
I then slid in the assembly:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0019.jpg
I wired up the battery pack and a switch next!

I didn't have any fresh AAA's, so I used my rechargeable ones to power it up:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0021.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0020.jpg
Looks like I ordered a Red/O for this...I couldn't remember if I got a Red or a Red/O, and this is definitely Orange!
But not as bright as I thought it should be...so I checked the battery pack voltage with my multimeter, and was only getting 4.08 volts...tested all batteries individually, and there was a dead cell in there. (It must've been the one from my son's mp3 player!) I popped them into the charger to charge them all up to the same level.

I got home from work around 2:30 a.m. this morning and they were all evenly charged:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0022.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0024.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0025.jpg

Much better! It's shown here using one of my 3/4" blades with a full roll of Ultra's DIY Ultrafilm. I still need to add some Corbin to this blade or sand it to help give it that solid energy beam look instead of the beam of light in a tube look, and also get it all re-assembled and cleaned up!

[Malaki Skywalker]

Sweet Jay-Gon! It came out awesome! :D :cool:

[Darth_DevilGuy]

that came out nice, I wish I had those kinda tools on hand.

[ArkaiHalon]

it is coming along very nicely. very nice indeed. can't wait to see the final product.

[Hasid Lafre]

May i noticed in your images you use what appear to be greena dn blue rechargable batteries that look extreamly clse to the ones that me and my bro used to use.

Might want to be carefull with them as the ones we got after a long while they actually started to suck themselves in like the + end was sunk in flat like the - end would be.

Just an FYI on them batteries.

The red-o looks awsome in that saber man.


http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0021.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0022.jpg

[Novastar]

Great work, Jay Gonn!!! And really.... MUCH oblige for taking the time to literally take snap shots of things during the progress... and THEN to explain in detail what you were doing.

It really painted out the machining jobs that people might have to undergo in order to come out with a completed project.

Also... it makes me not feel so bad when I don't have all that kind of equipment! My sabers have never undergone such detailed processes!!

[Jay-gon Jinn]

Hasid, you mean the Rayovac ones or the Digital ones? I've been using the Rayovac Hybrids for over a year in my mp3 player, without any trouble. The Digital Brand I just got from Wal-Mart to use in that player because they are 1000mah and the Rayovacs were only 800mah, and I gave it to my son and he won't be using it everyday like I did at work. either way thanks for the heads up, and I'll keep an eye on them.

[Hasid Lafre]

There blue and green.

[Jay-gon Jinn]

Both sets of rechargeables in those pics are blue and green.....

[Hasid Lafre]

Ok well one set looked close to the other but ther not rayovacs that I know. Just some cheap name brand rechargables.

[DACOTA]

How did I miss all of this?:eek: Great job! I really love the whole el conversion to led, its just really cool. Its like justice was served getting the el crap out and the led hero in. That sounds like a crack head. Oh well. Thanks Jay, this will most cetainly brighten my hopes for when I convert E7H4N's randomsaber to led. Man I just cant get over how cool it is to take a sweet el hilt and lux it up. :mrgreen: A thing of beauty!

[BlackDOG]

might I suggest, since the term "REDNECK" was used earlier,.....using my Reneck Inverted Drill Press (RIDP)...
http://img.photobucket.com/albums/v294/Birdlaw/5563116c.jpg

If anyone cares for a explaniation...I would be glad to give one....otherwise enjoy my "gloroius lack of sophistication"


BD

[xwingband]

If anyone cares for a explaniation...I would be glad to give one....otherwise enjoy my "gloroius lack of sophistication"


BD

That's the craziest jury rigging I've ever seen... it took me a bit to figure out that was a car jack.

Jeff Foxworthy speaks the truth also.

[Jay-gon Jinn]

Okay, Alias, maybe it was these, then:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0013-1.jpg

BlackDOG, that's an interesting use of a jack and cordless drill, looks like something I might've thought of!

Anyhow, I took some time yesterday to make the blade set screw. I had a very nice chrome 10-32 socket head screw that had come with a water bottle for a bike and thought it would look nice on the saber. Trouble was, it was 3/4 of an inch long. Time to fix that:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0001-1.jpg

After I Mounted it in the vise on the drill press, I used my rotary tool with a cut-off wheel, and shortened it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0002-1.jpg

One piece of advise if you ever do this: DO NOT PICK UP THE CUT OFF PIECE OF SCREW!
I absent-mindedly did just that and got this to show for it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0002_00.jpg

That hurt.... :o

After some serious cursing took place, I popped in a blade and checked the screw's fit:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0003-1.jpg
Looks like that'll work!

The blade in these next pics is one of my 3/4"thin-walled Dual-Core diffusers with a single wrap of Corbin's film and about 6 feet of polypropylene (cellophane gift wrap).
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0005-1.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0006-1.jpg

I took these pics for this build with my old Kodak DX4330 and it got these looking pretty close to what it looks like in person. I know how to use that camera a bit better than my newer Kodak Z612 camera.

With that all done, I can start to put it together again!

[Jay-gon Jinn]

My original plan with the heatsink in this was to have the three body screws thread into it to help keep it in place...I decided against that though, and put the grip section in the drill press and drilled down another 1/8" to help the heatsink clear the screws:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0011-2.jpg

I put the hilt together again:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0008-1.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0009-2.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0010-2.jpg

I'm really not liking that switch....it barely fits in the hole...and prevents the pommel from going back on as it stops the battery pack from going in any further:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0007-1.jpg

I have some other switches I can use:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0015-2.jpg

I plan on trying to modify a Parks switchbox that I orded from his Saberkit website to hold one of these switches, but I have no idea when it's going to get here....I do have a few other parts that need to be re-attached so maybe in the meantime I can do that. The face ring on the emitter needs to cemented or glued on...any recommendations for doing that? I was thinking JB Weld....

[Hasid Lafre]

Yeah Im 85% sure that them are the batteries we had trouble with.

Looking goood with the saber there jay, cant wait till its finished and sanded smooth with a nice bit of polish.

[DACOTA]

Yeah go with the jb weld, that stuff is like rock when it dries, you can even use it to glue engine parts together, at least thats what the box says.

I love how you post the progress, its like were there watching you, you put it all together and then crap, the pommel doesnt go on, oh well i'v got some other switches, lets see what weve got, ok this looks good.[Then you see the pic of the switches.] And its like your talking to yourself while were there, your like, "I'm really not liking that switch....it barely fits in the hole...and prevents the pommel from going back on as it stops the battery pack from going in any further"-Jay-gon Jinn. Great job man.:D

[Jay-gon Jinn]

Yeah, I'd like to take credit for coming up with posting in that style, but I got it from my friend Jedi Tim at Saberknights...he's the machinist that did my custom saber for me. He posts a project page for every custom job he does, and walks you through the build-up of your saber....and if you're really lucky to be able to be around when he has his webcams going in the shop, you actually watch your saber being made!

As far as the work on this saber goes, though, i am stalled until that switchbox i ordered from SaberKit.com comes in.....

[BlackDOG]

I am interested in seeing the switch box.......I reused one from my old EL saber and I would like to se how yours works out........I went on park's site....which one did you use jay-gon?

BD

[Jay-gon Jinn]

I ordered th "R" style box...I have yet to hear that it's shipped....

[B5813]

It always seems to take a while to get items from Parksabers... I also have another R box and Graflex style clamp on order... close to two weeks now. Definitely not the turnaround time you get with TCSS!!

[ArkaiHalon]

It always seems to take a while to get items from Parksabers... I also have another R box and Graflex style clamp on order... close to two weeks now. Definitely not the turnaround time you get with TCSS!!


Amen to that. And the fact that I live less than 40 miles from them, and they still charge me an arm and a leg for shipping.

[Jay-gon Jinn]

Yeah, this will probably be the first and last time I order anything from there.

[Jay-gon Jinn]

Update!

I decided to use a small sliding switch from radio Shack on this saber, and after receiving the switchbox from Parks' Saberkit site, I decided not to use it. It was just to freaking big! So, I decided to finally try my hand at making a switch plate to cover the switch hole from the old push button switch. I'll also need to move the switch forward on the hilt section, so some cutting with my Craftsman Rotary tool will be required.

I stared out by drilling another hole just ahead of the existing switch hole, and then used a simple file to square up the hole. It turned out like this:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0006-2.jpg

I drilled and tapped a #4-40 threaded hole for the mounting tab on the switch and test fit the switch:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0007-2.jpg
That'll work!!

Now to find something to use for the switch plate/cover plate....I'm thinking something in brass:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0008-2.jpg

Using a piece of graph paper, and my dial calipers, I drew a simple pattern up and applied it to the brass tube:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0009-3.jpg

I'll be using my rotary tool with a cut-off wheel for this (along with a steady hand!)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0010-3.jpg

I loaded it in the drill press' vise and started cutting:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0011-3.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0012-2.jpg

Set the tool to a middle of the road speed and keep your hand steady:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0013-2.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0014-3.jpg

I swapped out the cutting wheel for a sanding drum, and de-burred it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0015-3.jpg
I also rounded the corners a bit.

[Jay-gon Jinn]

I also drilled out the two holes for the mounting screws, then marked off where the center hole for the switch button needed to go:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0016-2.jpg

I used a center punch and hammer to make a "dimple" to keep the drill bit from "walking."
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0017-1.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0018-1.jpg


The hole isn't big enough to allow full travel of the switch, so it's time to use my trusty side-cutting tungsten bit to elongate the hole, turning it into an oval-shape:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0020-1.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0021-1.jpg
Make sure your tool is on a slower speed, otherwise, the bit will bite and take off on it's own, leaving you with a bigger hole than you wanted.

this only took a few seconds:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0023-1.jpg

[Jay-gon Jinn]

I test fit it on the saber:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0024-1.jpg

That should do....now I need to drill and tap some mounting holes for the plate:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0025-1.jpg
I used one of the kevlar gloves from work to prevent damage to the hilt from the vise. It worked...no new marks to polish out.

I wasn't sure if I wanted to try and polish this pece, but decided to go ahead and let it tarnish over time and with handling later. I used some Brasso on it, and it turned pretty nice:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0026.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/000_0027.jpg

[savyas]

wow. That turned out pretty nice, but what a whole lotta PITA that was for you! Would a thinner sheet of brass plate have done the trick?

My local hardware store (handyacehardware.com) has various thicknesses of brass and copper sheet metal that I've been considering using. So far I've only bought a variety of brass screen patterns and brass metal strips, but this has given me some new ideas.

[Jay-gon Jinn]

It was actually really easy to do, and I already had the brass tube sitting here, and it was already curved. i just had to bend it a bit more in a pair of channel-lock pilers to match the hilt. I may have to look though, and see if my hardware store has any type of sheetmetal, that's a good idea.

[Jay-gon Jinn]

Well, I have it pretty much finished, and took a few "beauty shots" after cleaning and polishing. You'll notice I left the dmaaged ares alone, and just polished it. I think the damage adds character to the saber, and gives it that "used" look:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/100_1908.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/100_1909.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/100_1911.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/100_1924.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/100_1926.jpg

It's basically done, but I still have one minor detail to do something with:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/100_1922.jpg
This hole needs something...I was thinking that it might look good drilled through to the blade tunnel, and put a clear plastic cabochon in there and have it light up with the blade.

[ArkaiHalon]

Looks really good Jay-Gon.

as for the hole on the side. one idea would be a brass thumb wheel (or similar) to serve as a control knob. The clear jewel idea is good too

[Jay-gon Jinn]

It actually used to have a little brass thumb knob right there, but it got in the way of handling the saber. I'm leaning more towards the acrylic plug....

This has been a fun project, but this saber definitely lived up to it's name...it's been a real PITA to get done. Just makes it that much more satisfying I guess!

[DarthFender]

Jay-Gon, if you didn't pull half you hair out over it, it wasn't fun. :wink:

[Jay-gon Jinn]

Just a quick update on this one! I actually did figure out what to with that hole in the side of the hilt. I drilled it all the way through into the blade socket and made a small acrylic plug to fit inside:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/d55ee883.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/d57638a7.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Agony%20lightsaber%20pics/8fb9c194.jpg
I do believe this saber is finished! (Well, as finished as most sabers get, anyway ;))

[MoonDragn]

That looks great Jay! I don't like those type of switches either though, It looks like you have enough room for a Vandal style switch maybe you could put one of those in there. The switch just doesn't look like it fits on such a beautiful saber.

That little hole you had in the side, have you ever considered putting a push button switch in that hole that had the button top flush with the side of the saber. Like a little recessed switch?

Since I was derailing the other thread about the 3/4" blade, we can try it in this one, do you see any drawbacks of using a 3/4" blade in this saber? The reason I'm asking is because I was thinking of using a smaller blade on a Luke ROTJ style saber with the thinner neck and the fan, but that neck is only about 3/4" in diameter.

[sekrogue1985]

Impressive!

[Jay-gon Jinn]

That looks great Jay! I don't like those type of switches either though, It looks like you have enough room for a Vandal style switch maybe you could put one of those in there. The switch just doesn't look like it fits on such a beautiful saber.

That little hole you had in the side, have you ever considered putting a push button switch in that hole that had the button top flush with the side of the saber. Like a little recessed switch?

Since I was derailing the other thread about the 3/4" blade, we can try it in this one, do you see any drawbacks of using a 3/4" blade in this saber? The reason I'm asking is because I was thinking of using a smaller blade on a Luke ROTJ style saber with the thinner neck and the fan, but that neck is only about 3/4" in diameter.

There's not enough room for an anti-vandal switch, they go too deep into the saber for that. The quad-AAA battery pack actually fits underneath that switch a bit, so I'm stuck with it.

The hole in the side goes all the way into the blade socket, so any switch I put in there would be just for looks, really. I like the acrylic plug, it makes it look like it has an accent led that comes on whe the blade is activated.

The only real drawback to the 3/4" blade is the dimming I get near the blade tip. I could probably eliminate that with a small piece mirored film, though. I just don't want to take the blade apart to do it.