A step by step of my brother in laws saber

[Darth Midian]

I started on my brother in laws saber today. I thought I would take pics and explain my process.
1. I get my pvc stock & parts. 1", 1 1/4" pvc, 1" male & female connector, & black o rings.
2. I cut the main body of the hilt from 1" pvc. I cut this stuff by hand. I don't have a miter saw yet.
3. I cut the shroud & grip from the 1 1/4" pvc.
4. I make the templates for the grip & shroud. By the way a paper towel tube is excellent to use as a template for 1 1/4" pvc.
5. I pre-drill holes by all the curves & corners to make it easier to cut out. I then use my dremel to get a rough curve for the shroud. Then I take sandpaper & wrap it around a can of spray paint to get an evan curve.

[Darth Midian]

I know I'm not suppose to double post. I just don't know any other way to post more than 5 pics.
6. I cut out the shroud & grip.
7. I take my dremel and sand & shape the shroud & grip.
8. I piece the hilt together & plot where I'm going place screws, windows/holes, led/heatsink, & switch.
9. I take masking tape and tape the shroud & grip to the hilt body. Then pre-drill & drill all holes.
10. All the parts are cut. My next step is to do the finale shaping & sanding by hand. I use 60, 100, 150, & 220 grit. This is all I have for now. I'll keep you all posted. Thank you.

[Shadar Al'Niende]

Double posting like this is ok


oh and i just have to say:

I LOVE IT! KEEP IT COMING!

[Knighthammer]

Amazing PVC work! Keep it up - must see completed.
Good thing I've orders some 1w LED to make my own =)

[Ulstergeki]

i cant wait to see it painted, youve got me interested in pvc again haha.

[thejedilestat]

<---- thats suposed to be my jaw droping



good work 2 thumbs up

[Tom Starkiller]

Ace!!

That's some sweet PVC-fu you have there.

[Master Dai Bendu]

Very Nice! Keep the pics coming!

[HAVOK]

..............................


AWESOME!!!!

seeing this makes me want to build another... its like and itch that I just cant scratch ....

[Darth Midian]

Thank you everyone. I'm planning on picking up some wood inserts and screws this weekend. I'll get the final sanding done, and start painting it. I'll be taking pics. Again thanks.
Havok, I know what you mean. I keep getting new ideas all the time. I can't stop thinking about lightsabers. OH! STOP THE INSANITY!