I've found a solution to all the problems in my saber (I guess). See pic.
From the pommel to the holder it's just a 9 inch extension with a bit of lathe work. No more thread problems, it's cheaper than my previous designs and in the future I could make a drill on it for a switch to turn it into a full functional lightsaber the way it's meant to be!. What do you think?. I also colored it a bit with photoshop to see how it could be in the end. By the way, about the o-rings in the choke section, maybe it would be possible heating the o-rings to insert them in the choke and then cooling them. If anyone wants to try, please tell me about the results.
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