2007 Master Replicas Luke ANH Conversion
What I have:
2007 Master Replicas ANH Hilt (gutted prior to me getting it)
Graflex 2.5 red button with post
Graflex 2.5 glass eye replica
Graflex 2.5 D-Ring
T8 Tubing
Craft Boxes, Hardware, and Burlap
micro tactile switches
Guinness can, yep, I have those.
Shopping List: (sans tools, wire, etc.)
B,B,W Tricree with transfer tape
Carclo lens
TCSS Luke ANH Conversion Kit
.5 ohm resistors
NBIV
MHS V6 Chassis
18650 Battery Holder and 18650 battery
28mm Veco Bass Speaker
TCSS Short Graflex Pins
...and we're off:
I wanted a Maz Box for this one, not movie accurate, just a box built to look like an old wooden box.
Here is what I started with Pine Craft Box/Hardware lines are going to be etched to look like planks:
https://i.imgur.com/jTMKkzom.jpg
Next, I cut the lines so it looks like planks, then burn, dremel, mar, and scar. FIRE!
https://i.imgur.com/99MdnZjm.jpg
Add Stain, and hardware, and oilah, it looks like an old box that has been in Maz's place for hundreds of years.
https://i.imgur.com/NJvycMNm.jpg
Lined it with some padding and burlap over padding. Box fit for Maz!
Saber:
Step one, can the old DRing. Its too small, you can't even attach it to a saber clip. I popped it out with a drill, and popped on the 2.5 DRing instead. I used a rivet, she's in there solid. Here is comparison shot of the 2 drings prior to surgery:
https://i.imgur.com/f4N7b4Dm.jpg
Step two: I wanted to do a momentary switch in the clamp on this one. I'm doing another MR Graflex (Rey's Jedi Training Hasbro), and I'm going to give red button activation a whirl on that one. I got rid of the latching switch here. I dremeled out the existing switch hole to allow for the new tactile switch hat to poke up into the clamp. The micro tactile switch was then intalled there under the bubble strip. Got rid of the factory metal underneath the bubble strip, and replaced it with some layers of aluminum beer can trims until I got the appropriate response out of the tactile switch. It took 3 layers of beer can trim. I trimmed the aluminum in a solid rectangle with no slots, so that it prevents the clamp card from sliding forward as it did from the factory with the latching switch.
Photo of the tactile switch in the clamp:
https://i.imgur.com/jzW5eesm.jpg
Step three: Prep the conversion kit. I painted the round recesses flat black where the short graflex pins go. I drilled out the stock MR Electric tabs so that they fit the TCSS Short Graflex Pins, so I could re-install them. They are chrome, and should be brass, but looks better with them than without. Installed the new LED Star on the heat sink and popped the conversion kit into the saber after de-burring the inside of the saber per Tim's advice. The fit is tight, but accurate. I have no complaints about the conversion kit, none. I think its awesome. I also drilled and tapped the conversion kit to receive the Graflex 2.5 Red Button and Glass Eye. Threads are 10-24. I did have to mill down the base of the red button so that it fit in the button receptacle, but that took a minute. Simple.
Arrival of the TCSS Conversion Kit!
https://i.imgur.com/vYj5lQIm.jpg
Red Button (you can also see the black paint in the graflex pin cutouts)
https://i.imgur.com/aDQRJIdm.jpg
Glass Eye Replica
https://i.imgur.com/OhcLuDCm.jpg
Step four: Prep the MHS V6 chassis. I trimmed the battery holder, wired it, wired the speaker, and attached the NBIV aboard. I went ahead and soldered the speaker wires, but left the positives and negatives off until they joined with the wires coming from the saber (LED+ and Switch - will join with battery leads and then onto NBIV). I also cut a piece of T8 tubing and routed the saber wires into the tube, so that the tube could be later slid over the MHS V6 chassis, once the install was complete.
Step five: Route the wires into the MHS V6, join where appropriate, and solder in the board!
https://i.imgur.com/bSj9u1Am.jpg
Finished Saber:
https://i.imgur.com/WmFVZEJm.jpg
https://i.imgur.com/5jbapeUm.jpg
Insert blade (new red button is blade retention!) and rock and roll!
Video of her in action:
https://youtu.be/u_7Rt7Gpfa4
Tom
