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Hand File + MUCH patience+practice=great results.

Aluminum tape with a tiny hole in the center works nice. And you don't have to mess with any glue. It also acts as a good way to make the 3/4" copper caps that some of use as heat sinks fit better in...

It's been built before this.It does take MUCH skill to wield.

http://forums.thecustomsabershop.com/showthread.php?8922-Modular-Weapons-System

Nice idea with the colored duct tape, DM! I was thinking about doing that for my kids' saber class when we do daytime demos.

I've been using 3/4" pex in the sabers I build for the kids' saber...

I like the mixture of wood and metal elements. But you might want to smooth out the edges on the wood grips. Otherwise, it's a cool concept!

Go down the electrical supplies aisle at your nearest home improvement store. They have pre-bent electrical conduit in pvc and metal. They should have 45 and 90 degree curves.

Get the cross slide.
It makes lining things up SO MUCH easier. I got a regular one first 'cause that's all Home Depot had and it was a PITA.

I don't know much about much, but is your diagram missing a line from the positive of the recharge port?

I don't know much about much, but I would try to wire it the same way as the 2010 Hasbro sound card.
I haven't gotten one yet.

Funds are so tight I can't even pay attention.

This might be a good option for the econo-pvc sabers I'm gonna build for the kids who join my lightsaber class.
Thanks for posting!
======Runs out to buy one========

Update: Went to the...

No apologies needed! I was just responding to Jedi Loreen's post and there are other sabersmiths on this forum who discovered this trick also. Even though I thought I came up with this, a few months...

I did. Just ask Darth Midian.;)

Nice tutorial!

I'm really surprised this isn't well known.
This trick has saved me many $ over the last couple of years.

Try a building a sinktube saber, all you pretty much need now is the TCSS sinktube bladeholder and a blade! Check out some of Jay-Gon's hilts.

Kipher:
Most people use a small section of the Hasbro saber's blade as an enclosure for the electronics. I've done it a few times myself.

Good luck with the rest of your build!

Me too! I've found some really cool ones at cigar stores. They usually sell empty boxes for like $1 each.

I had the same problem with a really old hasbro board. Never figured it out either, I went through every wiring combo possible and even tried a new transistor. I was using a Red Lux III, so I took...

Just happen to have one right in front of me!

The Obi Wan saber's code is 653569529682.And the box says:
Star Wars The Clone Wars on the left top side and
Obi Wan Kenobi Electronic Lightsaber...

Nice work!
It's proof that it's the artist not the tools!

I have to say, a drill press is a must have for any shop, not just for sabersmiths.
I bought mine for building sabers, but it's helped me on a bunch of other stuff, too.
And don't forget a...

It's new to me!
Somehow I missed this one.

That's gonna look cool!

I did something similar awhile back:

http://forums.thecustomsabershop.com/album.php?albumid=74&pictureid=598

Here's the thread tapping tutorial:


http://forums.thecustomsabershop.com/showthread.php?t=5724

I got this 1" belt sander on sale + I had a 20% off coupon, I think I paid ~ $30. It has a real small footprint, too.

http://www.harborfreight.com/1-inch-x-30-inch-belt-sander-
2485.html

You...

I stopped using the cut off wheel in the dremel , 'cause of too many flying pieces. Now I hold put the bolt/screw in a nut, hold it with a vise grip and use a belt sander to take the screw down to...