First Custom Build Thread: Ezra Inspired Saber from a Vintage Camera Flash
Hello there!
A while ago I acquired a 2005 Master Replica Vader Saber from a local thrift shop, and converting it to a single LED detachable blade saber really got me interested in building a custom saber of my own. Combine that with the fact that I recently started watching Star Wars Rebels, and what I had to do became clear. I started first by scouring eBay for a vintage camera flash gun. I'm sure that almost all of you know that Luke's lightsaber in ANH was made from one of those, but I'm typing this out anyway in case someone who stumbles across this thread might not already know that bit of trivia. I have a 3d printer, so I figured I could design and print a new set of internals to fit into the shell that will hold the new guys. I didn't have much of a budget for the flash gun, but I found one I could afford. It was in very rough shape, so I decided to make that my aesthetic. Here is a photo of the original condition from the eBay seller:
https://i.imgur.com/9NBFdmF.jpg
I already had a design in mind, so I set about creating a rough sketch of the desired layout. Here's my first drawing:
https://i.imgur.com/fRxhcRH.jpg
Next, I waited for it to arrive. Once it arrived, I realized exactly how rough of a shape it was in. The thing still had D cells in it from when it was originally used. I'm no expert on how long ago that was, but given my very basic understanding of the technology's era, the batteries could have been stuck in there for 30 years or even more. Certainly at least 20. This was a problem, as they had degraded so much it was impossible for me to get them out without damaging the thin metal of the body. I ended up using a Dremel to cut away some of the casing, allowing me to get a grip on the first battery. After that, the second battery was easy enough. Unfortunately, that cutting with the Dremel removed about 2" of material from the end of the handle. This made my saber hilt more of a dagger hilt.
I decided to adapt my design to have a 3d printed pommel and shrouded emitter, both of which would add some much-needed length back to my design. Here is a rough sketch of the next iteration of the hilt:
https://i.imgur.com/JISHzCn.jpg
Next, the 3d design and fabrication began. I started with the blaster attachment that would clip to the place where I assume the flash gun would mount to the camera. I wanted it to be both functional and detatchable. A few design iterations later and I had this beauty:
https://i.imgur.com/nuMe7hv.jpg
The ring serves as the trigger for the blaster attachment. Currently, I plan on mounting a 100mw laser module on the inside. I'm hoping it will be enough to pop balloons and light matches, but we'll see. Unfortunately, this design for the trigger was not sturdy enough. Originally, the ring was attached to the post after printing with epoxy. This was not strong enough, as the ring could be snapped off if pressure was applied from the side. I reworked the ring so that it prints pre-attached to the post. Now the post is inserted nto the hole in the blaster shell and screwed into the bar that connects the post to the return spring and micro switch.
Here is a picture with a test fit of the blade:
https://i.imgur.com/EKRiuPr.jpg
You might notice that the red activation button is missing in the last few photos. This is because I hadn't actually finished designing the internal scaffolding that would connect the red button to the micro switch. Soon after these pictures were taken I had an idea how to design that part, and I managed to make a pretty nice activation switch mechanism. I do not have any pictures of the interior parts, but I promise I will take photos when I get the soundboard and other internals soldered together. Additional to the main switch mechanism, I also added a hole for a set screw to secure the blade. This caused some problems, as the threads on the top of the set screw were too thick to fit into the existing hole in the flash gun's activation switch shroud. I attempted to drill out the hole slightly, but the shroud snapped. It's fortunate that I want the saber to look beaten and worn. I just JB Welded the two fragments back together and applied a fresh coat of black paint.
With the main switch mechanism built, it was now time to focus on the pommel. Originally, I planned to make the pommel screw in with some threads. This did not work, as the tolerances were not fitted. It was impossible to screw the pommel into the other end even after some heavy sanding. I decided to rework the pommel to be a friction fit. This seems to be working well so far.
Here is a picture with the first pommel installed:
https://i.imgur.com/qoe7IQJ.jpg
I say this is the first pommel because I later remembered that I wanted to have a D-ring for attaching the saber to my belt. As such, I needed a centered hole in the bottom of the pommel through which to mount the D-ring. I tried to do this with a drill, but I wasn't satisfied with the results so I ended up reprinting the pommel with a hole added to the design.
Next, I focused on the emitter shroud. The first print did not fit right, but after some slight adjustments to the file I was able to print a shroud that fit and looked good. Here is a photo of that:
https://i.imgur.com/ej2hmsu.jpg
That takes this post up to my current progress. I still need to order some of the components for this build, but I am hoping to finish at least the saber by the end of February. Hopefully I can also finish the blaster addition by then, but that is mainly dependant on when AliExpress decides to ship my laser module.
I hope you enjoyed reading this post, and I look forward to updating it as I progress further with my build!
