Here is the first rendition of an assembly for the Obi hilt. It is sitting on the Emitter right now just as a way to hold it up for photographing. It will of course slip inside the hilt sections in the end. You can see here an O-ring at the upper end, and the white vanes at the lower end. These are the exact size of the Hilt's ID, so they hold this whole assembly very snug when it is in place. The over all lenght of this so far is about half of the available space in the hilt, so I will still need to fill the rest. To this end I have not made any "permanent" construction here, I have just tacked this Crystal Chamber together for testing.
Here you can see the solution to the attachment problem I was talking about previously. Rather than glue the crystal socket to the armature, I slipped it in the central hole, and used some winding wire to wrap it. The wire had a nice lip to rest on creating a very elegant way to attach them.
The beginning of the assembly process.
Here the 440S can motor armature is fitted to the bottom of the "crystal Chamber". I cut the motor shaft just above the rotor where the brushes would have run. I then polished this rotor down about 1/64" so it would slip into the bottom of the Crystal Socket.
As in various Light saber Lore, there were actually up to 3 "Crystals", I have placed a "Krayte Dragon Pearl" as a secondary "Crystal".
There are tons more picture of various parts of the assembly, the testing process, and various crystals etc. If you are following this thread, you really need to check the link to my Sky drive account, where you can find many more pictures.
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