Machining the Emitter (with large image)

For the body of the lightsaber, I have an inner diameter of 1” (Will any battery packs fit in a 1” ID?) and an outer diameter of 1.5”. I’m going to use the 1” OD blade and all the wiring from this site. Below is a diagram of what I plan to make for the emitter. Is the 1/2" hole (in blue) too big? Will the led fall out? What are the dimensions for the led, collimator lens, and lens holder? Any help would be much appreciated; thanks.
Hooray for paint!
http://img421.imageshack.us/img421/6558/diagram6rm.png

I don't know why you'd want such a thick tube but I believe 1/2 is not too big. Someone else can chime in but I believe 1 inch is not enough for the LED or it would barely fit in there.

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i'm going to use the lathe to cut it down. i just wanted some room to make a design on the hilt

will a 9v battery fit in the 1" ID of the hollow tube if i use a soft batter clip, or do i have to have a 1-1/8" ID?

A 9V wouldn't fit in my heiland (ID slightly less than 1 1/2) so I'd say it's a definate no. The diagonal dimension of the 9V would be well above 1 inch. I don't think a AAA pack would fit either. You might be restricted to running whatever batteries you get in series.

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the diagonal of a 9V is about 1-1/16". i think it will fit in 1-1/8" ID.

When you put the led, collimator lens, and lens holder all together, what is the greatest diameter?