My first build (x3) - pic heavy

First of all I have to thank this board for all of the great information and inspiration. I have lurked for the past few months during this build and this forum has helped me tremendously. I wanted to make a couple of custom sabers for my two nephews (5 & 7) both of whom are star wars fanatics. I also decided that I would need to prototype one to work out the kinks, which I will be keeping for myself :D. I designed the entire saber in Solidworks, less the wiring. Once I finish up the drawings and assembly instructions I plan to post it all on grabcad. I also have a mostly complete bill of materials with sources and part numbers/prices if anyone wants it.

Same design x 3.
#1 is Blue with White FoC
#2 is Green with White FoC
#3 is Amber with Red FoC.

Nano Biscotte V3 sound board
Rebel Led
tri-star MCPCB
MHS Heat Sink V3
18° tri-rebel optic
28mm Bass speaker
18650 Battery
712A recharge port
Ø1.0 x .125" wall trans white polycarbonate tube
White shouldered blade tip w/ reflective tape
16mm sst antivandal switch (short)
7P Tyco pcb header
7P Tyco connector & pins
JST connectors
28 awg control wire (multi colors)
3D printed internal chassis
3D printed kill key
3D printed blade plug (not shown yet)
Machined aluminum hilt, switch plate, pommel, and blade holder.

Brainstorming
http://i.imgur.com/D8CtZ6D.jpg?1

Design
http://i.imgur.com/7Kda5P6.jpg

Design
http://i.imgur.com/FGpJTAm.jpg

Machined Parts
http://i.imgur.com/n7wmInV.jpg
http://i.imgur.com/W6ED0Wr.jpg
http://i.imgur.com/peBQPtV.jpg

Adding header to PCB
http://i.imgur.com/mQInxSw.jpg
http://i.imgur.com/4cb5a2v.jpg
http://i.imgur.com/XY2ZnaH.jpg
http://i.imgur.com/gEIjZac.jpg

Soldering LED Star
http://i.imgur.com/ilADmAt.jpg
http://i.imgur.com/7Tap3Lh.jpg
http://i.imgur.com/SkVQfxw.jpg

Starting electronic assembly
http://i.imgur.com/UxnPz9G.jpg

LED Wiring
http://i.imgur.com/n558pa1.jpg
http://i.imgur.com/qie02pn.jpg

Thermal Tape
http://i.imgur.com/61DNIMz.jpg
http://i.imgur.com/UxUmNI7.jpg

Resistors
http://i.imgur.com/KF4DfXi.jpg

Finished LED Assemblies
http://i.imgur.com/7rfPK68.jpg

Optics
http://i.imgur.com/zAsf638.jpg
http://i.imgur.com/2SZsJrp.jpg

Speaker wiring
http://i.imgur.com/jfGGSq8.jpg

More boring wiring – JST connectors, etc
http://i.imgur.com/AkIQefH.jpg

Testing
http://i.imgur.com/uTJFpyw.jpg
http://i.imgur.com/nd6mcSt.jpg

Some finished pics
http://i.imgur.com/jCjK6wt.jpg
http://i.imgur.com/BorXk1N.jpg
http://i.imgur.com/kBH2WRK.jpg
http://i.imgur.com/CVryt4R.jpg
http://i.imgur.com/xpr5AAf.jpg

Impressive.

I like that amber color.

Welcome to the forums. Nice work. Looks awesome.

Just a side note. If the list of supplies, parts, etc. contains items not from TCSS you should probably not list them here. These forums are attached to a store ;)

Keep up up the good work.

Quote:

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Originally Posted by darth_chasm

Welcome to the forums. Nice work. Looks awesome.

Just a side note. If the list of supplies, parts, etc. contains items not from TCSS you should probably not list them here. These forums are attached to a store ;)

Keep up up the good work.

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I understand. Really the only other sources I used were Mouser electronics and luxeonstar, no rivals. I wanted to do the surface mount soldering of the leds myself for these. I would say about 80% of the stuff came from TCSS. BTW their shipping turnaround is top notch!

Added a couple more and finished them up in time for Christmas. I foresee some happy kids in a couple days!!
http://i.imgur.com/oQ8exWi.jpg?1
http://i.imgur.com/MvZ8yTo.jpg
http://i.imgur.com/DTRKlQY.jpg
http://i.imgur.com/SWSjljX.jpg
http://i.imgur.com/hSzYH98.jpg
http://i.imgur.com/mVyv79b.jpg
http://i.imgur.com/74QRw58.jpg
http://i.imgur.com/GuGCer6.jpg