Blade tip making

Hello everyone, i hope i chose the right part of the forum to start this thread.

I'm living in Russia, and have no access to lightsaber parts most of you can just order online.
And i make most of the parts from the material i gather locally.

My current issue is that i'm using the polycarbonate tube to make lightsaber blade. PC tubing is locally made, so its using a metric system and have 25mm outer diameter, instead of 25.4mm (1 inch) most of you use. Inner diameter is different too. So, blade tips does not fit to my blade. Of course i can order normal blade tube and tip from TCSS, but it will take around 1 month to delivery and will be heavily costly, due to the shipping price.

So, there is a question.

How can i make my own blade tip that fits my specifications?
What material and crafting methods should i use?

I will appreciate any information.

With best regards!

If you can get solid polycarbonate rod and you have access to a lathe, you should be able to machine your own blade tips.

You can use Methylene Chloride (Weld-On 16) to attach the tips to the blade. Chloroform will also work.

If you don't have lathe you can always use a drill and sandpaper, but it is dangerous rough method.

Silver Serpent, thank you for reply and tips.
Is TCSS balde tips made using this method you describe?
Access to lathe is painfully hard to get here, it's easier to buy tabletop lathe, i guess it will be enough.
Or i could try to find transparent PLA plastics and try to print it on 3D-printer.

boikonur, it is really dangerous method, and i would not try this at home. I love my fingers ;)

By the way, i have another question.
From what material are reflective discs made of?

I'm not sure what the TCSS reflective discs are made of, but you can use the material from the anti-static bags that you get electronics in. I usually get a bunch of it when I order computer parts. Just cut circles out of it, and glue in place.

Silver Serpent, thank you.
If original material is unknown, i can also try 3M reflective tape, for instance.

You want a material that lets some light through, and reflects the rest. If you use a perfectly reflective surface, then the tip will not light up.

TCSS Blade tips are made on a CNC lathe. To make them on a manual lathe would be tricky. You either need to carve your own cutter out of high speed steel on a bench grinder or use a radius cutter.

The reflective disk is or used to be mylar.

Back in the day we made our blade tips from acrylic, not polycarbonate. If you can find a local store that stocks acrylic hemispheres (cabochons) then you can use those. They are attached with Weld on 3 or 16 just like polyC ones. The downside is if you duel a lot with your saber, those tips pop off very frequently.

You could also make one out of clay, make a mold then cast one in clear resin. It would probably be heavier than desired, but it could work in a pinch.

pezzer75, it is a really good idea.
I should try this method.