MR Vader pin removal

[MasterStoddard]

I'm converting a co-worker's MR Vader and I can't seem to get the pin in the switch box out. Can you please recommend how to do it so I can reuse the blasted thing when I put the saber back together? I've tried using pliers and the narrowest pin punch I own. I would greatly appreciate any help that you can give.

[Lord Maul]

On both the Vaders I have converted, I have ended up just cutting that pin out. You can make a new one out of a smaller cotter pin.

[Rhyen Skytracker]

Yep, I have had to cut mine out too and make a new one.

[Mobius]

Nooo dont cut it out....

just press on the large pin from the back and use a pair of needlenose pliers to pull the pin out. just make sure that the pin is parallel with the main tube of the lightsaber.

[MasterStoddard]

Mobius, I've tried the way you recommended several time with no luck. I've only been able to get the pin half way threw the large pin but can't get it the rest of the way out.

Lord Maul, what size cotter pin did you use? So if I decide to go that route I know exactly what to ask the hardware store clerk for.

[Lord Maul]

I don't know exactly what cotter pin I used. I found one in my parts bin and then just cut it down to size.

[MasterStoddard]

I don't know exactly what cotter pin I used. I found one in my parts bin and then just cut it down to size.

Having a bit box is always the sign of a master. Thanks tho. I guess if cut it I just take what I can still find of it or the large pin to Home Depot or Lowe's to see if I can get the right size and hang on to what is left over if I ever convert another one.