Custom Hilt, reveal chassis, cf9 w/ cex build
This is one of the more involved commissions I've been given the honor of building. The trick to this one will be space management, I like to make all my hilts as slim as possible, most falling just over 1.25" in OD, this makes fitting intricate chassis a challenge. Especially when the client requests a fully loaded CFv9 w/ CEX and no single cell hack....We will see how this goes!
https://i.imgur.com/7UkrLRpl.jpg
Here is the design sketch that was approved by my client, the size is not to scale, but it gives an overall layout of how it will go together.
https://i.imgur.com/lVcubQVl.jpg
https://i.imgur.com/EOQnaYZl.jpg
https://i.imgur.com/EvkZqMal.jpg
I approached this one a bit backwards and started with the shrouds. These will still receive a fair amount of filing and sanding to get everything straight and perfect. They were cut from 1.25" copper tubing using the trusty dremel.
https://i.imgur.com/qcyuijYl.jpg
Found some good cutoff spare pieces of aluminum to use for the main hilt...let the machining commence. I use a Grizzly G0516 Lathe/Mill Combo. Overall the machine works well, its the first heavy machine i've ever purchased, if I had it to do again I would buy the lathe and mill seperately, the lathe is hampered by having the mill attached but I find most milling jobs to be hindered by the limited workspace.
https://i.imgur.com/aJdaFXPl.jpg
https://i.imgur.com/BNdmoY3l.jpg
https://i.imgur.com/o8Oix5Fl.jpg
https://i.imgur.com/3Ta5Bu2l.jpg
https://i.imgur.com/ExOOHnUl.jpg
https://i.imgur.com/h3SIDyEl.jpg
Both halves came out really nice and the shrouds fit perfectly snug without marring the finish of the aluminum. Next will be only my second attempt at threading so fingers crossed I don't ruin these beautiful pieces lol. I will practice on scrap until i have the whole process down.
After the threads are done, I'll be boring out the bottom half a bit more to help accommodate the batter and board being sandwiched to help maintain space. All the main electronics will be housed in the lower half to allow for the top to be an intricate crystal chamber.
Finally the main hilt pieces will have windows milled for the various reveals and finally the chassis work will begin.
Thanks for looking!
