Galen Marek sink-tube Starkiller

[ghost_a*]

this is my first ever attempt at a custom lightsaber. doing sink tube + PVC inner
i have very minimal tools and skills at my disposal and i admit that this is a bit ambitious for my first one, but i'm trying to replicate, as best i can, galen marek's lightsaber in the force unleashed.

i'm using roland at http://ro-lightsaber.blogspot.com/ as my inspiration and modeling as he has some very high resolution pictures of the one he machined.

here are some pics of what i have so far.
i started with the electronics and crystal for the exposed crystal chamber, but that i'm going to come back to.
i need to get some more doo-dads (screws/hardware) to continue there.

so i went onto the hilt.

started with a 1.5"x12" sink tube
dremeled the tip off, then shaped the s-curve emitter
then i made my own template for the rest of the upper emitter section, dremeled that out.
that's pretty much done for the base shape. i still have to drill the holes for the activator box and knobs.

next i'm moving onto the base section of the hilt.

for the chassis i'm using PVC.
i plan on using some kind of adhesive padding to stick on the interior of my sink tube parts to make it more flush against the PVC when i mount them together.

here's a few pics of what i have so far though:

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[Rafalema]

You're off to a great start!

Ambitious project, but the first pics give the impression that this guy knows what he's doin'.

Keep up the good work, and good luck on your first saber! I'm sure it won't stay as your only one for long!

[Knighthammer]

good start - keep it up!

[ghost_a*]

thx guys. i'm pretty psyched about this so far. i just wish i had more time to really dedicate to it.
feels like i get 20 min here, 30 min there.
wife and a 7 month old baby girl limit my 'free time' for doing stuff like this.

hopefully i can get to lowe's this week to get some hardware to start mocking up the metal to the PVC.

also, i need to find a decent speaker for the audio. any tips on where to find one?
i have a cheap rinky dink one but the sound quality coming out of it is mediocre at best.
i'd like to buy one from TCSS but adding shipping would pretty much increase the price 100%.

[Azmaria Dei]

since the store sells one i can't tell you where else to get a speaker. besides that, it's worth it at thrice the price.

[Jedi-Loreen]

A lot of research and trial by various people have gone into choosing the speakers that Tim carries in the Store. They are very good, and nice and loud.

[cardcollector]

Yeah, the Tcss speaker is the best out there IMO. Plus it is only $6.

[ghost_a*]

gotcha i'll most likely go with that one then.
i'll continue to update with pics as i go along, this'll just be pretty slow going.

[ghost_a*]

so continuing on with the hilt fabrication, i made a quick trip to lowe's and got a thread tap for 8-32, got 8 bolts that match the images i've seen of the galen marek saber.
6 of them i'll use to mount the emitter sleeve to the PVC chassis.

i also got some felt pads that have adhesive backing.
i'm going to cut them to shape and stick them inside the sink tube parts in order to make the chassis fit snuggly inside the emitter sleeve and lower sink tube portion.

the next steps are going to be to continue fabricating the emitter sleeve upper portion (activator box, bunny ears, buttons, etc.)
and to carve out a section of the PVC chassis for the crystal chamber.

i'm going to need to sit down with a pencil and paper to start to mock up a drawing of the crystal chamber as well.

[dgdve]

Very Impressive!! (double post lol) but yeah the saber is off to a great start too