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Very cool idea for the batteries! Love how this turned out.

You did a great job on both. I think my eye is drawn to the Shoto more because it feels like the weathering is telling a story. I am also really loving the brass piping on the emitter.

Yeah, Home Depot has some crazy prices for the small fastener stuff. Sadly it's the only option locally sometimes. =[

It seems they have different names from each store, almost as though "expansion bushing" or other such names are copy written.
I honestly only found them by scouring the small bits section at my...

Perhaps a thin plastic sheet could be cut to fit between the activation box and body? Maybe .010 or .005 inch THK polycaronate sheet?
Some larger heat shrink could possibly solve the ring contact...

This looks awesome, I almost didn't believe you on the fact of PVC, nice work!
The blade plug is pretty rad too, I love how it works with the simplicity of the emitter.

The plug I posted is a mish-mash of the wonderful ideas from this forum, and I am very grateful for everyone's sharing nature!
Blade plugs really do add an awesome look to the saber when on display....

Thanks for the inspiration and parts details!

https://flic.kr/p/DrViTj
https://flic.kr/p/DjE8y9

Hopefully I can end up finding some more interesting parts to make more of these.

I noticed that, at Home Depot, the expansion bushings are called "dowels" in the fastener isle.
Hopefully that helps some find parts.

Oh man, that AV switch does look amazing in that pommel.
I have to second what Generic Jedi said though, you won't get much sound unless you modify the pommel or find an insert solution.
Maybe a...

I like the design you have there, it has all of the aggression associated with a sith! Hopefully the blade shroud won't end up too sharp though, lol.



For any parts that need to be held to the...

Following with anticipation of the final product.
It's looking awesome so far, thanks for sharing your process!

Switch in the threaded zone for your first saber, very impressive effect achieved!
I like the blade plug, is that a sink aerator plastic screen?

Simple and elegant saber, I love how the gear transitions to the pommel! I really like how compact the chassis is.
Do you have any pictures of the pommel with the switch in?

It's looking great so far!
Is most of the detail done with a rotary tool?

Sounds good, I'll pop down to the store tomorrow and grab some more resistors. I might as well test a bit further, seeing as this is my first electronics project.

Thank you for clearing up my...

Using 3.7v as my power source and running the LED at 1000mA, I ran the numbers through the equation.
I am currently using a 1.2 ohm/2 watt resistor, by using the online calculator (it rounded up...

Definitely the way to do it, just be cautious that other items don't start disappearing from your cart.
That recently happened to me, so I need to reevaluate my options.

On topic of the sleeve...

I decided to practice my soldering and wiring techniques on a PVC stunt saber before ruining a sound card. Other than a few parts being out of stock, I was almost done with the project until I ran...

What is your preferred method for sanding the inside of the tube?
I've wanted to sand my blade for a while now, but can only imagine this task being quite difficult unless I only sand the exterior.

I didn't even think about that, I'll probably go and pencil in some color.
Thank you for checking the diagram and pointing out the color tidbit!

Awesome, thank you for checking!

This will be my first saber build and major solder project beyond the practice I've done.
I am still trying to learn the use of each component, so the diagram is pieced together from other reference...

I've noticed recently, when trying to wait for all my parts to be in stock, that a few other pieces end up disappearing from my cart due to going out of stock.
I can totally understand the shipping...

Awesome, I'll have to give it a shot once I have the shroud shaped. Thanks for the quick response!