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Jay-gon Jinn
05-07-2008, 04:58 PM
I don't know how much interest there is in these anymore, but I did some more work to Brass Sabers 4 & 5 today. I started by cutting the angle for the emitter shrouds:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2088.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2088.jpg)
I thne used my tubing cutter to cut off the shrouds from what will become the rear half of the hilt:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2089.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2089.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2090.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2090.jpg)
After that was done, I polished the shrouds, because I had the same issue as last time with the saw leaving burned edges on the cut, and when that was done, I used the tubing cutter to make the rear grip marks:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2091.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2091.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2093.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2093.jpg)

Next, I measured for the screw holes to mount the MHS adaptors:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2094.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2094.jpg)
I transferred that measurement to the brass tube:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2095.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2095.jpg)
I marked it with my exacto knife, by leaving a small scratch, and took it to the drill press and set it up to drill the hole:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2097.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2097.jpg)
After drilling the first hole in the brass tube, I slipped in the MHS adaptor and using it's pre-drilled and tapped holes as a guide, drilled straight through to the other side of the brass tube:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2098.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2098.jpg)
Doing it klike this ensures that the hole on the other side of the hilt will match up perfectly with the hole in the adaptor, making everything symmetrical.
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2099.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2099.jpg)
See what I mean? I did them both while I had the set-up in the drill press. Here's what these two (three actually, the chrome hilt piece seen above is being worked on along with these two) will basically look like when done:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2100.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2100.jpg)
And while I was drilling holes, I decided to drill these for the switches as well. Here's how they turned out:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2105.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/100_2105.jpg)

Now I have to play the waiting game on some parts from the store before I can complete these.

I have some leds on order, but haven't decided what colors I'll use in these....I also don't have any sound boards, so it may be awhile before these are completed.

37H4N
05-07-2008, 09:05 PM
Looking good! I always love your brass sabers and brass sabers in general. I want to make one of my own someday. I may change the sinktube saber idea I had into a brass one.

DARTH KALEL
05-07-2008, 09:22 PM
wow, I really like that idea. they look great, i've got a few small sections of mhs I might try that this weekend

eastern57
05-07-2008, 09:43 PM
I think it's justified to say that you've rightfully earned the title of "Master of the Hardware Sabers" or "MOTHS"

...or something similar that actually sounds cool...:)

GFORCE13
05-07-2008, 10:07 PM
Very Nice I love how they are coming out, I am in the process of buying brass pieces to customize my 2 MR Jedi Joe Sabers and be able to make a Saber Staff out of them.

Jak'Kan-Ur
05-08-2008, 04:44 AM
Yea i'm gonna have to go look at brass as well!
thanks great Idea's

B5813
05-10-2008, 08:47 PM
Brass is purdy. Jay-gon, what do you suggest for keeping the brass clean outside of polishing it after every use? I've used a pretty solid 1 1/4" brass tube from online metals joining the MHS pieces on both ends with the 1.5" sink tube adapters. The brass is sweet for a while but quickly gets tarnished after handling. I sprayed it with a clearcoat but that didn't stick... it rubbed off after a while of use.

Jay-gon Jinn
05-11-2008, 01:30 PM
Well, the only way I've found to keep them shiny is to not touch them. The oils in our skin cause the tarnishing, so maybe put some gloves on, when wielding your saber? I've thought about using some clear laquer paint on some to see if that would help....other wise, I just use some Brasso on a soft cloth and clean them after use.

TD-2272
05-11-2008, 01:55 PM
Hey Jay try Never Dull it's found in the auto department at Walmart it works great.

Jay-gon Jinn
05-11-2008, 02:05 PM
I have some already! I also have some Mother's mag and aluminum polish, which works really well, too.

SpectreT65
05-11-2008, 02:14 PM
As to blade color - for some reason, Jay, your designs scream "Green" to me time and again. Probably because of the patina oxidized brass takes on. :D I've got a sinktube I was planning on sanding down to the brass, inspired by some of your designs and Corbin's "Killer Penny". Frankly, I've mainly been wating on better weather and better tools, and I've been worried about the tarnishing as well. "Weathered" isn't a look I'm going for. More like "well-oiled and cared-for favorite tool". :D

Jay-gon Jinn
05-11-2008, 02:30 PM
I'm going to make one of them red, just to see how it looks. The other one will be green or cyan (bin 6, pastel green!). The chrome one is going to be blue. I should be able to finish these off later this week, The parts from the store have shipped, and I have a line on some soundboards as well. I'll be trying out some new speakers I found, hopefully, they'll work.

Leigh
05-11-2008, 03:16 PM
Your sabers look the nutts, I really like lines with the pipe cutter & Brass is just lovely to look at & work with.
Have you tryed using Autoglym resin wax polish to reduce tarnishing? if you put a few coats of the polish on after youve used brasso it should build up a nice protective layer of wax, It works on freshly cut Alloy wheels, Just an idear

Hasid Lafre
05-11-2008, 03:38 PM
I would so love to see one of these "electrom" sabers in a red blade.

That would be so sick looking.

Jay-gon Jinn
05-13-2008, 12:50 PM
After receiving a couple of soundboards in the mail from Eastern57, I got to work on one of the sabers. One of the soundboards doesn't quite work (it's barely audible, and I'm working on that) but the other worked fine. I prepped both for installation, and I'll start with the Mace Windu board:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0803.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0803.jpg)
I had to replace a few wires on this one, as the stock ones didn't meet my wiring code colors. I replaced the purple switch wires with my standard blue wires, the speaker negative is now brown, the speaker positive is now yellow. I also soldered on the disconnect for the led. I hot glued the clash sensor to the board, and glued down the wires I replaced to prevent them from coming loose. Here's a few more shots of this board:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0804.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0804.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0806.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0806.jpg)
I made sure the board worked and shrink wrapped it:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0807.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0807.jpg)
I then did something I was going to do on the last two brass sabers....I wired in a recharge port:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0808.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0808.jpg)
I drilled a hole for the port (using a 5/16 drill bit in the drill press....sorry no pics of that, you've all seen me drilling holes before!) and began the installation:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0809.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0809.jpg)
This saber is intended to use either rechargeable NiMH or standard alkaline batteries(do not attempt to recharge alkaline batteries in this saber!!!!). The charger and the plug adaptor for this set-up can be found in the TCSS store. While attempting to install the switch after putting in the recharge port, I realized I needed to have the switch installed first, so I swapped them around and got it all in there:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0810.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0810.jpg)
I installed the ribbed extension and then the heatsink with the led, and fired it up:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0811.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0811.jpg)
This one is about as far as I can go now....I have to wait for the UPS truck to deliver th rest of the parts....that won't happen until Friday, though, according to their tracking data.

Jay-gon Jinn
05-16-2008, 11:29 AM
I got to work on Brass Saber #6 today...it's sister #7 will be worked on next. Here's what I did:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0830.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0830.jpg)

I started by cutting the angle on the end of the tubes for the emitter shrouds. Next, I laid out all the locations for the holes by wrapping the hilt tube in graph paper. I then drilled the mounting holes wor the MHS adaptor, starting with just one, and then slid the adaptor into the tube and drilled through it to the other side of the brass tube. This ensured that the two holes would be directly opposite each other. After completing that, I noticed that the holes were not quite centerd on the hilt in respect to the grip window edges, and just adjusted the pattern to compensate. I then drilled for the switch hole with adaptor in place. (I hope all this lines up right, I don't have the rest of the parts yet!) I thought I'd take a couple of pics to illustrate what the finished saber will look like:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0834.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0834.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0835.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0835.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0833.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0833.jpg)
These next two will be kind of a mix between BS#1, shown below BS#6, and BS#2.

Next I started cutting the window for the ribbed extension to show (just like BS#2!):
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0836.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0836.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0837.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0837.jpg)

After some filing and sanding with the rotary tool, I was done:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0838.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0838.jpg)

I threw the MHS adaptor in there, along with the switch:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0839.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0839.jpg)

I should be able to get a little further with this one on Friday after the rest of the parts get here!

Jay-gon Jinn
05-16-2008, 11:39 AM
Well it's Friday, and the rest of the parts arrived! (Well almost....somehow, I ordered one less blade holder...so the chrome saber will have to wait).

Here's what I got:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0842.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0842.jpg)
All the parts for the chrome saber, except blade holder....

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0843.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0843.jpg)
Parts for Brass Saber #5

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0844.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0844.jpg)
The rest of Brass Saber #4

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0845.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0845.jpg)

Brass saber#7, the sister saber to this one, Brass Saber #6:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0841.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0841.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0840.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0840.jpg)

Now I have some work to do.....

Jay-gon Jinn
05-16-2008, 02:51 PM
Okay, this didn't take as long as I thought it would....
I got both Hilts #'s 4 & 5 drilled and tapped to mount the shrouds, and then set up the drill press to drill for the blade thumbscrews, and them tapped the holes by hand. (These will all use 10-32 screws):
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0850.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0850.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0851.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0851.jpg)

Since I had the set-up in the press, I did hilt #6 as well:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0852.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0852.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0853.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0853.jpg)

I soldered up all the leds to the TCSS copper heatsinks (these things are heavy!):
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0854.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0854.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0855.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0855.jpg)
I made sure to use a little CPU paste under wach led to help with heat transfer. The red one got a little extra, as the red leds have a history of grounding out on the star base to the heatsink, and shorting the led.

The last step was to hone the blade holders using my 1" cylinder hone from McMaster-Carr.com. This ensures that each saber will be able to use a variety of blades from different suppliers. I do this last as this removes the burrs from drilling through the blade holder into the blade socket. I'll hit the one for BS#7 again after I drill it for the blade thumbscrew.
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0856.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0856.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0857.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0857.jpg)

And finally, since BS#4 is all wired for sound already, I popped in one of my sanded Dual-Core Diffusion blades and shot some pics:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0858.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0858.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0859.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0859.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0860.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0860.jpg)
These were taken using a bin 6 Cyan Lux III, which produces a nice, pastel green blade.

Now for those of you that prefer to walk the Dark Path.....
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0862.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0862.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0861.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0861.jpg)
Same blade as before, but with a bin 2 red Lux III. All of these hilts feature the TCSS style quick-change led kits, making swapping leds fairly easy. (Hilts 6 & 7 will be a bit more difficult to swap leds in than 4 & 5.)

On to the machine work for the chrome saber in the bunch, then after that, I'll get started on BS#7.

Hasid Lafre
05-16-2008, 03:36 PM
looks nice jay

SpectreT65
05-17-2008, 12:25 AM
Bin 6 cyan, eh? Nice. And the red looks pretty slick with the brass, too...

heh. When I get married, I may just give my buddies some hardware stunt sabers. They'll all appreciate them, I know that.

Jay-gon Jinn
05-17-2008, 05:54 AM
They'd be more used than say, a coffeee mug or something, I'm sure!

Kant Lavar
05-18-2008, 12:31 AM
Oooh. I love that brass saber with the red blade.

I might have to consider attempting to do that if/when I do another saber. (First, though, I'm still waiting on a couple extra parts for my first one!)

Darth_Razor
05-18-2008, 05:16 PM
Very nice sabers.

Jay-gon Jinn
06-07-2008, 04:31 PM
I finished off another of the brass sabers:
Brass Saber #5 is done!

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0885.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0885.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0886.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0886.jpg)

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0887.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0887.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0888.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0888.jpg)
I replaced the cheap plastic switch with a more expensive, but better looking metal one. It also doesn't cause the saber to power up cycle if you bump the switch like the plastic ones do.
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0889.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0889.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0892.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0892.jpg)
The recharge port is directly beneath the switch. This isn't easy to do, but I managed to get it in there. This is the same as what I did to BS#4 and CS#4. To make the saber rechargeable in the hilt, just install 4 NiMH 1.2v batteries, and get a smart charger and plug adaptor from the Store. The difference bewtween this one and BS#4 is the grips. This saber has a v-grooved ribbed MHS extension, and features 3/8" spaced grip marks on the rear of the hilt.
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0891.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0891.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0890.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0890.jpg)
To access the batteries, you just unscrew the nut from the hilt, remove the washer/foam/strainer, pull out the speaker/resonator assembly....
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0896.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0896.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0895.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0895.jpg)
pull out the battery pack by pulling on the blue wire attached to it, and change the batteries! Reverse the process to re-install. Very simple! I do all of my sabers like this.
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0894.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0894.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0893.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0893.jpg)

I also finished off Chrome Saber#4:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/2ac75140.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/2ac75140.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/a7aa4ff0.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/a7aa4ff0.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/b915a581.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/b915a581.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/a26a0ba9.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/a26a0ba9.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/789b6440.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/789b6440.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/e4d394de.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/e4d394de.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/e4047f55.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/e4047f55.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/afa26c00.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/afa26c00.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/93c3eb8f.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/93c3eb8f.jpg)
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/c7b06569.jpg (http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Chrome%20Saber%204/c7b06569.jpg)

I think it turned pretty nice! It has the recharge port wired to also act as a kill switch during recharging, has the improved metal push button switch from the hardware store, and also has a recessed speaker grille. I did this by using the same laundry strainer I used in the MPS pommels of BS#2 & 3, except I didn't cut it up like those two. It just fits in there with rubber gasket around it and is held in place by the nut. The nut I actually got at Lowe's, and looks like it is intended to reduce a 1.5" plumbing drain down to a 1.25" tailpiece. Regardless, it looks cool on the saber as a pommel/end cap! Sounds good, too....I shot short video of it, but haven't uploaded it yet. I made the blade for this one and also for BS#5 during a Tornado warning yesterday. I had no idea how close the storm came to my house until I was on my way home from work this afternoon! Trees and roofs ripped off less than 2 miles from house! :o

EDIT:

Here's BS#5 with it's blade:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/69d935bf.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/6e709212.jpg
Both sabers use a 36" (34"exposed) thin-walled polycarbonate blade with internal sanding and about 5 feet of cellophane wrap.

Darth Anubis
06-07-2008, 06:36 PM
I love the Chrome Saber it looks sweet

Drichar Deis
06-07-2008, 11:49 PM
and very shiney!

CorellianBada**
06-08-2008, 12:12 AM
love the emitter shroud on the chrome. ***eh!

BhujangiJedi
06-09-2008, 03:27 PM
As usual, really nice stuff Jay!

I have developed a newfound respect for the quality and precision of work you do with these sabers - I just built two very simple, basic sink-tube sabers and it was hell! It's very difficult for a noob to get a nice cut and exact placement of holes. Luckily, they turned out functional, which is what I was aiming for, if not beautiful.

Jay-gon Jinn
07-07-2008, 01:00 PM
After a very long hiatus, I decided to finish off BS#7 today!

I started with the wiring ofthe MR Luke Skywalker ROTJ soundboard:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0960.jpg
I added some scoring lines to the emitter:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0978.jpg
This saber also has one of the metal switches I get at my local hardware store:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0977.jpg
I put scoring lines on this one at about 1/4 of an inch apart to simulate the rear grip:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0979.jpg

I slid all the electronics into the hilt and put 'er together:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0961.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0962.jpg

Here you can see the recharge port and the CT knob:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0963.jpg

Like the rest of these brass sabers, to change out the batteries, unless you're using NiMH rechargeables, just unscrew the end cap:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0966.jpg
Then remove the speaker/resonator assembly:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0965.jpg
Pull the battery pack out by tugging gently on the orange wire:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0965.jpg
And Voila:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0964.jpg
I happened to have a red led mounted, so I used that to start off with:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0973.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0974.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0976.jpg

It also features the TCSS quick-Change LED System:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0967.jpg
One advantage this has over BS#6 is that I split the emitter shroud form the sleeve. I found it to be a challenge to swap out the led, so I modified this saber. Simply unscrew the emitter, and remove the lens assembly:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0968.jpg
Select the desired color of led:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0969.jpg

And re-assemble, then you're good to go:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0970.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/000_0971.jpg

I hope everyone enjoyed reading about this build as much as I did doing it! This is the last one one for awhile, as I need a bit of a break from building. Maybe after the OT at work slows down a bit.

Jay-gon Jinn
07-07-2008, 01:11 PM
Not to double post, but I just realized I never posted anything about BS#6! It was finished about a month ago, and turned out pretty good too:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/9aa9ce8e.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/c759ecc8.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/72ecbf9a.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/0c7573c7.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/a59047c5.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/b93d200e.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/4ff8cd58.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/79cb74ae.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/My%20Brass%20Sabers%202%20and%203/Brass%20Sabers%204%205%206%20and%207/76136fe9.jpg
This one, like BS #'s 4 & 5, features the optional recharge port, as well as TCSS's quick-change led kit. Changing the led is a bit of a job, though, as it's hard to get hold of the blade holder. It is shown there with a Cyan bin 6 led, but i also have a red Lux III that I could pop in there as well. It uses 4-AA batteries, just like the ones before it, and has an upgrade to a TCSS Premium speaker, in case it ever gets a better soundboard, which btw, is an MR Luke Skywalker ROTJ.