Solaren's Essence Build Log (First-ish Saber)
So my first batch of parts finally arrived! It may look a little confusing, but half the parts I wanted were out of stock and the blade holder and pommel were both pretty low when I bought these. I picked up enough odds and ends to start working things out spatially, so my first few posts will be more proof of concept progress.
http://jonathanlequire.com/solaren/e.../essence00.jpg
http://jonathanlequire.com/solaren/e.../essence01.jpg
Day one progress will be posted after work.
Day Two: Attack of the Pommel
So, I've had a few false starts on parts of this project since I last posted. Mostly just tinkering to figure some things out, so nothing to really show from that.
Today, I tackled the speaker mount/pommel situation. One thing was very clear after my first dry fit of the chassis parts: I chose the wrong speaker mount to go with my pommel. The pommel 3 V2 has so much space inside, it is practically a mini extension. Would it work? Sure, but it may have required extending the design by an inch. Or, I could modify the V5 mount I got and make it into a V4 which would slide down into the pommel and still leave plenty of room for a recharge port inside.
I was planning to make some modifications for wiring the recharge port and an accent LED or 2 around the speaker mount anyway, so I started by sanding down the lip that locks the speaker mount in place and test fitting it in the pommel with the recharge port. Sitting flush with the end of the pommels threads there was about 0.2" of clearance (as measured by one of the metal chassis discs sandwiched in between the two parts) between the face of the speaker mount and the recharge port connections. I think this is enough room, if not the speaker mount can back out of the pommel to allow more room, it will eventually be held in place by a set screw.
Then I marked out some locations for wiring, cut a guide with a cut off wheel then rounded and shaped them with a cutting bit. Realized that each channel was only going to hold one wire, so I added 4 more channels, and this is the finished speaker mount:
http://jonathanlequire.com/solaren/e.../essence10.jpg
After the mount was prepped and test fit with wires I moved on to soldering the accent LEDs I had picked out for the pommel, a 2Hz flashing power indicator and a wide angle conical top led that will light with the blade. The conical top spreads the light around the pommel nicely and looking directly inside it doesn't blind you.
All the parts ready for a test:
http://jonathanlequire.com/solaren/e.../essence09.jpg
And assemble with both LEDs on.
http://jonathanlequire.com/solaren/e.../essence11.jpg
YouTube videos: Blinking Power LED & Both LEDs at once
Now that I've stepped back and watched the videos I think maybe the 2Hz LED is too fast, I may step it down to a 1Hz. And depending on the sound card I eventually get it may or may not stay on with the other LED.
Day Four: New Parts, Switches V1.5
Second shipment of parts arrived today! Not pictured, blade material and cap. Still waiting on a Prizm to make it across the pond from Erv.
http://jonathanlequire.com/solaren/e.../essence17.jpg
Test fit of the exterior pieces, its a little longer than I had imagined...maybe the interior pieces will let me cut an inch somewhere.
http://jonathanlequire.com/solaren/e.../essence18.jpg
Today I worked a bit on the second iteration of my switch setup. Here is the interior view of the first pass.
http://jonathanlequire.com/solaren/e.../essence19.jpg
Turning a piece of dowel into a plug that will hold the switches in place without relying on hot glue.
http://jonathanlequire.com/solaren/e.../essence22.jpg
Final pieces for the assembly. The grooves in the choke were cleaned up a bit to even them out, a 6-32 hole was added to secure the switch plug. For the plug I used the dremel to create a couple matching grooves to allow the plug to tighten a little closer to the choke, then drilled holes in the back corners to hold the prongs of the switches and allow wires to pass through, finally I bored a hole to allow wires from the main LED to pass through.
The switches come with four prongs (unmodified switch on the left), to fit into this assembly I break off the prongs on one side and straighten the other set out (middle switch), then add a thin layer of hot glue to cover the remaining metal of the broken contacts because that side will be pressed into the aluminum of the choke (visible on switch sitting in the plug.
http://jonathanlequire.com/solaren/e.../essence20.jpg
And a test fit shot of this assembly. I'm much happier with this version, it is cleaner and has wire routing built in for later. I'm not going to wire these switches until I get the copper buttons turned and fitted. I will probably wait until I figure out how long the wires need to be to reach the Prizm and/or if I have room for some disconnects to allow for breaking the saber down easier.
http://jonathanlequire.com/solaren/e.../essence21.jpg