I finished this a while ago, but I'm just posting the pics now
Luxeon III Amber, 5 deg lens
1999 Qui-Gon Hasbro Soundcard
Only pieces I used from TCSS for the hilt were the 1 of: 1.25" Sink tube LED/Blade holder that I used as the emitter and all of the electronics. The rest were all spare plumbing parts I had lying around (thanks to my dad, who happens to be a plumber) with the exception of the outer brass covering which was custom machined.
I made the blade using THIS method stickied in the LED Blade Discussion section. Though, I doubled up on the amount of cellophane that was used in the tutorial. The blade is also removable via a spring loaded push and twist mechanism. There is a spring in the emitter, as well as two screws that hook into two L/U-shape cuts in the base of the blade. The spring keeps the blade tight against the screws.
I feel like its a little rough looking but overall I'm really happy with the way it turned out, especially with it being my first one (of hopefully many) and all.
More pictures here:
http://polyverseforge.blogspot.com/2009/05/lightsaber-2009-aerea.html
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