Boj-Vaati's One Handed Short Saber

[Boj-Vaati Mau]

I've had this static saber for the past several years and now, since the tech has gotten better, I feel I can get decent sound and light into the beast.


Emitter - I want to keep the bulb holder to help with blade stabilization. I'll need to epoxy the ring and cut out the center.


Pommel - I plan on griding out the base then the grill into it for the speaker.


And the interior space.There is a threaded connector in there that I'll have to work around but it shouldn't be that bad. Total space is 1 3/8" dia x 5 3/4" l.


On to disassembly and clean up. Emitter shroud after removal. I had this held with 4 pop rivets.


Bulb holder which, once I figured out it was threaded, came out easily enough.


Flash head which, until I figured out there were screws under the mylar tape, was a real pain to get out.


Disassembled & mostly cleaned up tube. I think I'll have to go with a spacer to tighten this up and get proper alignment. I've been having a heck of a time in lining it up again.


Here I have practiced the ancient art of Dremel-Fu. I've excised the guts of my 2010 Hasbro for trials. I've got the rest of the Econo Board bits on order but wanted to get an idea just how much Cram-Fu will go into this.


Cram-Fu in Action #1 - 3 Cell Battery Pack. As I'm going with a 2 Cell I should have a bit more room top & bottom.


Cram-Fu in Action #2 - Overall look-see for rough forward spce measure. vctrsone made a good calculation on aprox. 1"/30 mm after the Blade Holder is back in.

[Boj-Vaati Mau]

This installment we find our intrepid Jedi setting the mock speaker mount. I'm using this to gauge where the real speaker will go to get the best sound out of the hilt. It took three wraps of tape to get it stable.


I've got the Emitter snuged down into the mount and 4 layers of tape on it.


I did find out that two of the holes in the Emitter line up reasonably well with two of the rivet holes. I'll need to tweak it a bit to get it vertical then cut down the screws but it should work nicely. I'll replace the top one with the Blade Retention Screw.

[Azmaria Dei]

looks like it's coming along nicely! ^_^

[Boj-Vaati Mau]

Thank you, Az. It's been interesting so far & I'm certain it'll be quite the experience by the time I fire it up.

[Boj-Vaati Mau]

Well then, it looks like just in front of the rear screws for the grip/heat sinks will do nicely.


I suspected that leaving the old battery terminal holes open would help but, until I tested it, I didn't realize how much. I'll put a bit of mesh behind them then leave the spaces open To get something like this:

[Rafalema]

Looks great so far..

Just make sure to shorten those screws!