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Instructions on formatting the card are included in the pdf user manual for the card. I believe there is a link to it on the store page for this card.

You must format the micro SD card every single time you change the sound files. Not formatting the card will cause sound files to play incorrectly and to walk on top of each other. I forgot to...

I would be very interested in .IGS files of MHS sections that I could play with, mix and modify on my own. Making them individually on our own isn't hard, and I'm not sure how you would feel about...

Here is a wider shot of the desk. Definitely more play than work, but I used the work excuse to the wife when I built it. If you can't tell, I'm a Darth Maul fan. Red and black is kinda the overall...

The metal chassis works out beautifully. I used some 1.25" sink tube that has a brushed nickel plated finish. I tried out 2 different brands, and one had a bit more play in it than the other. The...

Now to plug everything in:

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_120134.jpg

Li-Ion battery in some cut and filed chassis parts from the saber shop:

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_115522.jpg

Inside new sleeve:
...

Version 1.0, econo board. Just thrown together in excitement.

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120926_123258.jpg


Version 2.0 in pieces:
...

Thanks for the compliments guys! As far as pics of the chasis, I didn't take any. I was too focused on getting her back together. Luckily, version 2.0 is much easier to remove than the first one....

I had to integrate the lens into the blade, and used the new style heat sinks to make up for the lack of space between the switch and the led assembly. This combined with the Novasound Neutrino...

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120925_125719.jpg

http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120925_131012.jpg
...

Nevermind. Problem solved. Loose solder

Right now with the nutrino, I have a red, green and blue LED depending on my mood. I'm currently scratching my head at the new board's behavior with the AV switch. Anyone else use the same...

I will update with wiring pics and some close up shots of the individual components when I make the time.

Pic update!

The blue and red led setup with the old hasbro economy board:
http://i747.photobucket.com/albums/xx120/Mav750k/IMG_20120818_220052.jpg...

Awesome

I only ask after searching for a few days already. I have some that look like a bit different shape on order, but it is the internet, so who knows if they will be any different than the set from Tim....

The JST\separate heat sink assemblies was my original plan, and I am continuing with it for the econo board setup. I have one assembly for each of the 3 colors. Right now I have everything working...

I have seen some RGB sabers built with switches for each color, and am not interested in adding knobs everywhere. The rotary switch would streamline that system incredibly. This demands more...

Wiring and chassis completed. I will update with pics when I get them. So far so good. Still debating the color choice for the main led. But I'm considering making an interchangeable set of heat...

Blue was the early favorite, but it looks like red has pulled out in front!

Sorry amwolf, I am a sucker for the more iconic blade colors I grew up with.

Thanks for the compliments everyone, she...

Poll added to thread for main LED color. Not saying it will be the deciding factor, but it will be nice to see what everyone thinks.

Thanks! I still have work to do on the inner chassis before getting everything lit up and humming.
I am also still on the edge of what color LED for the final install. Though my original intention...

There is some finish work for the middle ring to finish before attachment. I won't be relying on any one method of attachment. First, I need to notch the switch bevel so that it will overlap the ends...

As you can see, the pommel is meant to ressemble an Obi Wan prequel style. The entire saber is a combination of Qui Gon/Obi Wan. I have some square aluminum to cut and attach to the pommel. That is...