Cardcollector's "Rak Kazakh" Build thread

[cardcollector]

Hey guys,

I decided to take a few pics on a build I am working on and make a build thread. I don't know if any of you guys will benefit from it, but I thought some might enjoy looking at the way "I" build my sabers...

So, here are the parts for the saber, I must mention, the TCSS driver board is not going to be used. It was to expensive for the client.


So, I started with the activation box, since this will be the majority of the work on the hilt.


I measured and aligned all the holes with a caliper, and drilled everything out like so...


The box will be mounted on a 3" DF extension, So I had to drill into the threads. I also had to shave some threads off of the Male end of the Ribbed extension. A dremel cutting disk was used to do so.

That was way to stressful for me to be doing that again anytime soon...

Viola!


I will post work on the overlay tomorrow.

[Loachri MacTalabh]

Just speculation, but the reason you shaved some of the threads off the ribbed extension is accept the screw to the box. As you screw the two together, the recess will allow the pieces to fit perfectly. Smart idea, I like it.

[bk_renesis]

Hey CC just wondering why you drilled out holes for the box rather than making a cutout?

[Skottsaber]

Most likely because he doesn't have a mill.

[bk_renesis]

I performed a "cutout" on my first MHS that I updated with a control box using a dremel and files, worked beautifully. But on my contest saber I got Tim to mill it out. Either way works great. I just see the holes as being restrictive, I could be wrong.

[cardcollector]

Hey CC just wondering why you drilled out holes for the box rather than making a cutout?

Because drilling is quicker than cutting and filing. This one is on a rather tight schedule, so holes were the easiest route with this one.

And no skott, I have no mill.

Oh, and loarchi, that is exactly correct.

[cardcollector]

Double Post, but I think y'all wil forgive me.

Overlay time...
I decided to use MHS sleeve material for this overlay instead of sinktube as it will be painted... and the material is nice and thick.

First off, The template is glued to the MHS piece. Rubber cement is a favorite of mine to use as it keeps the paper on and peels off the metal easily.
ONe side...

and the other...


Using a dremel with a "Thin cut" disk... We get this;



And the other side...


Now to go to work with some files...



Much better, still not perfect, but headway is being made... I will come back to that side with some sandpaper later...

Now, back to the angled side, I traced the activation box around the overlay piece, cut it out, and filed it the same way...


Those hard lines bug me... let's take some 400 wet sandpaper to those lines...

Much better.
You can see a little ding in the lower part of the piece.. couldn't sand it out... it is there to stay.
The piece is also setup to polish. The paint it a trans blue, so The base needs to be somewhat chrome to make the paint job look right...

Finally, It is all polished up and ready to paint. (which I am doing this evening)



More to come soon...

[Xanatos1986]

I think this will look really nice I cant wait to see more.

[Tarrell]

Comming along nicely, Cant wait to see it finished.
Shame about the ding, but if you ever decided to weather it, im shure the ding will fit right in,

[Knighthammer]

So I've got to ask CC, is the vice just loose on the drill press? To me it looked like it might not be attached since you use it for you shroud work as well.
Just wondering cause I'm still having a hard time mastering the drill press / vice thing. (getting everything 100% lined up correctly).