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I gotta say that does look good for being just PVC based. I agree on the paint. I thought it was weathered. Given that it's based on Star killer's saber I would let it be beat up like that. I...

Wow. That is an interesting idea on using screws inside. Something I have thought of is using epoxy like JB Weld to secure it in place. Though I will have to make sure I only attach in to one piece...

HA! Found one already! In case anyone else needs it here it is.

http://forums.thecustomsabershop.com/showthread.php?1024-06-MR-Darth-Maul-Done-amp-kits-available

Would there happen to be one for a Maul saber that doesn't have the removable blade?

I had a feeling drilling and tapping would be involved on that. Sounds like a plan to me. And yeah any finishing issues can be resolved with sandpaper! :)

Greetings everyone! I know this thread has been untouched for a while but I figured I'd post a question here since. I'm getting ready to start making my first saber hilt and plan to use the sleeve...