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Yeah, those nuts look big. If you get the ones from the shop here, it'll work fine. Speaker holder will be snug.

Sure. As long as you can fit two resistors in the hilt OK, then it might be easiest to just leave the drive setting to max and just swap-out various resistors on your benchtop 'till you get what you...

Well, if you wanted to use a POT to play around with color mixing, I'd go for one of these, a 10ohm wirewound POT. Just use the center terminal and one of the side ones. But realistically, you're...

If you set "drive 940" in the config file to bring the voltage down to what the blue LED wants, you do not need a resistor for that LED, just the red one. Otherwise, yes, you would need two...

One of the arms, specifically, the arm that has the LED whose power you're trying to control (i.e.: the red one).

The "drive" setting adjusts the voltage, but not the current. It's used to set the output voltage to the nominal LED voltage for when the latter is very close to your battery voltage.

In this...

It'll be fine. I put both a recharge port and an illuminated AV switch in front of the speaker, and even all that didn't impact the sound. The pommel is one of the best places to put that port...

Your accent LED circuit should run from the 3.3V accent LED pad to your resistor+LED and then back to the negative pad on the NB itself (which is the negative node that comes back from the recharge...

Well, that is a problem. If you wanted to have the accent LED illuminate only when the main LED is on, you could maybe use one of these to wire the accent in parallel with the main. IOW, use the...

Exactly. The 3.3V pad for accent lights is the regulated internal voltage that the NB's computer runs on -- that never changes.

Yeah, right now, I'm shooting for a maximum length of what'll fit inside a 4" section without running into the threads, so maybe ~3"? I have the shorter 3.7V battery for that, and if it works, I can...

I have only used Disc #4 to build a two-rail chassis on the disc (with the speaker holder at the other end), then screw it down into the body just below the choke/ribbed section.

I'm also be...

Rebel Star Blue? Vf = 3.4. Vbatt = 3.7.

So, turn to page 17 of the NB manual: drive = 1023 * (3.4/3.7) = 940.

So in your config file, set "drive 940" and the voltage the NB delivers to the...

No. You're using a 3.7V battery. Buckpucks (at least the one's Tim sells, which are typical) are 5V min input -- they're for when you have higher battery voltages. You just need a resistor (if...

Dremel might allow one to mount the NB in the disc and then solder the header to the NB.

If this is your first build, you might want to piece the electronics together first without the chassis to ensure everything works the way you want.

I tried that myself, but found that there simply wasn't quite enough threading sticking through the bezel to make a solid connection. Had to just put the nut against the inner wall of the hilt, but...

https://upload.wikimedia.org/wikipedia/en/2/2c/Hellraiserbox.jpg
work backwards from the solution

Possible, but not probable. ESD damage is more of a danger at the component level. Complete PCBs are more likely to be damaged by improper connections, over-voltages, etc.

Certainly check the...

That cyan looks great, so great that I think I'll just run with that one on the next build.

Impressive. Most impressive.

Cut the groove down almost to the base of the speaker holder and make sure it's wide enough for all the wires to lay flat between the speaker edge and inner surface of the hilt. Run the wires...

That does look better, and you will have generous internal space. Though you might consider leaving the 4" grooved extension uncoated and maybe making the pommel green.

You're going to need to make your own chassis out of PVC or something because the NB/battery chassis disc holder is not going to fit in a ribbed section; it has a smaller ID than the standard hit...

Here's a very inexpensive 50W station that I picked-up some time ago.