Latest saber: The Accident!

[Eco]

Hey guys and gals, here's my ... 7th? saber, first full MHS saber and my fourth metal saber. (all in one)
This is the first saber that I've put sound in.

I call it the Accident because I was originally just buying parts to modify my first saber, Vissh, to put sound in it. But I kept making measuring mistakes, and before I knew it, I had bought enough new parts for a complete saber.

Which is just as well, because I don't like it. I'm going to redo the interior and make it look a little more professional with a chassis, add a simple overlay, and switch the LED to a Lux III Royal Blue, as well as get a transparent blue blade for it.
After that, this thing's going up for sale.

The Specs:
Lux V Green (Bin 4)
Two 3.7v Trustfires
MR Maul board (forgot to mention it in the video, but a big thanks to LDM for that, too!)
Lit AV Latching switch
6 inch fluted double female
Double male
2 inch double female
MPS pommel style 4
MHS Bladeholder style 16
Covertech knob

I'll post some pictures when I'm done with the full rebuild.
But for now, a video!
http://i85.photobucket.com/albums/k45/Eco_bender/th_MVI_1931.jpg (http://s85.photobucket.com/albums/k45/Eco_bender/?action=view&current=MVI_1931.flv)

(At the time of this broadcast, I've already completely dismantled and desoldered the entire saber. Back to square one!)

[Eco]

Hey, guys.
Here's an update on the Accidental Revival:
Finished my internal saber chassis. I'm quite pleased with it, considering that I was really just shooting from the hip on this one.
http://i85.photobucket.com/albums/k45/Eco_bender/IMG_1937.jpghttp://i85.photobucket.com/albums/k45/Eco_bender/IMG_1939.jpg
http://i85.photobucket.com/albums/k45/Eco_bender/IMG_1938.jpghttp://i85.photobucket.com/albums/k45/Eco_bender/IMG_1942.jpg
http://i85.photobucket.com/albums/k45/Eco_bender/IMG_1944.jpg

[ARKM]

Cool chassis man.

[Hasid Lafre]

It prolly wont happen but I would make sure heatshrink tubing goes in teh holes over teh wires as well cause constent use could cause wires to rub agenst the edges and cut throught the wire sheating.

Looks good

[ThreeQuadFive]

Awesome chasis, can you post the materials used for it?

[Eco]

@ARKM:
Thanks. :D

@Hasid:
That's a good idea, Not sure how I'll fit more shrink on there, but I'll definitely look into it.

@TQF:
Six 6-32 hex head 1/4" screws
Six 6-32 threaded aluminum spacers
Three 1/2" unthreaded nylon spacers, 1/4" OD
Twelve inches of 6-32 threaded brass rod, cut into 1/2" lengths
Two 1/4" ID x 1 1/4" OD fender washers with some holes drilled in them, (had to file down the outsides to get them to slide in the MHS smoothly.)
Four (Preferably six*) Rubber washers.
A 2.5" length of 1/4" ID heatshrink to insulate the bottom pole. Don't want to cause a short! :D

The rubber washers were so that I could leave the screws a little loose, so that during assembly I could 'wiggle' the rods around a bit. They also serve the purpose of acting as brakes for the sled, a couple of them extend beyond the edge of the fender washer and help grip the inside of the MHS.
*I would have used six, but the hardware store only had a few in stock.

All in all, the whole chassis cost me less than seven bucks. the most expensive bits are the aluminum spacers at a .65 a pop, followed by the brass rod, but there's enough there for two or three chassis.

[cardcollector]

*subscribing*

That is a great idea! That also solves one of my chasis problems...

Great info and Great Saber! What is a AV switch? I've never seen those before.

[Eco]

Sure you have!
The lighted Anti-Vandal switches from the store!

[Hasid Lafre]

You could try to drill the hole out bigger with a step bit.

[cardcollector]

Sure you have!
The lighted Anti-Vandal switches from the store!

OH, Duh...:roll::roll::roll:

I didn't have my wheaties this morning... Come to think of it, I didn't have anything!

[sekrogue1985]

nice accident!

[Kal El Rah]

I agree a very nice outcome to an unexpected accident, nice work on the chassis and a nice looking saber to boot .:);):cool:

[Eco]

Thanks for the compliments!

@Hasid:
I'll try something with the 1/4" heatshrink I have, but to get the board out, I'd pretty much have to cut off the LED leads. Which I would rather avoid.

[Hasid Lafre]

Well its somthing to try when you do have to take it apart again.

[Eco]

Hah!
I'd rather change "when" to "*if* I take it apart again".
I'd ultimately like this to be a one and done deal.

[Eco]

Just an update:
I've moved the Accident to the back burner for a while.
The one design flaw in my chassis is that the speaker wires twist up, and there's no room for any heatshrink. So while I ponder how to resolve this, I've set it aside. Also, my time has been devoured by the football practice season, so I haven't had much time to fiddle.
I have, however, finished the overlays, and I will post them later tonight, after practice.

[Eco]

Okay, I've been working on the chassis, trying to get the darn thing to stop twisting the wires. My attempts have yielded no success, so I have a question:
Is it wise to hot glue the speaker to the speaker holder? I suspect that's what's causing the twisting.

I'm about ready to give up on my chassis, I just don't see any way to fix the problem, and I'm running out of solderable wire. (Heatshrink and solder joints litter the line, and the hot glue on the board prevents me from replacing the whole battery line.)

That being said, can I get a sled spoonfeed? I'm even considering trying to find someone else to do the internals for me.

Thanks.