Kali Vidhvansaka's Light Saber

[Boj-Vaati Mau]

So I've gotten into this build the last few days as it took a bit to get all the parts togeher. The first image is the evolution of the design as Kali kept seeing different things she liked and took a bit to settle down on.



She'd finally settled on the last design and I'd widened the Tail End Shroud. The copper will be baked on Hammered Copper from Rust-Oleum and I'll use upholstery grade vinyl for the green leather.



The process of getting up to where the shroud work is today.







These weren't too bad to cut out. Most of the roughing was with a Shoe Maker's file then cleaned up with a 1/2 round Mill bastard and Finishing files, and finally sanded with 400 and 1000 grit sandpapers.



This was fun as I'd broken 2 fine and one coarse Jewler's Saw blades, cut a channel with a Tugsten Carbide router in my Dremel, drilled a batch of holes and then broke two drill bits cutting between the holes. The smoothing procees went back to the router bit. As you can see, I've got the back part cleaned up and finished so today goes to cleaning up the front.



And here's a color study of the copper, green vinyl, and aluminum.

[Boj-Vaati Mau]

Here we are at the end of the day...

[brett]

There looks to be a lot of work gone into this, and the results are great! Interesting and original design, will keep my eye on this build, thanks for all the images. Always inspirational to see what others are doing.

[Boj-Vaati Mau]

Thank you, brett. Quite a bit of hand work when you don't have belt sanders and large drill bits! My wife is waiting as patiently as she can for it to be complete.

[DemonBunnyman]

looking good

[Nichos Seastrider]

Definitely digging it. Looking good!

[Boj-Vaati Mau]

Thank you, gentlemen. I'd finished the drilling and tapping for the shroud work but stuck the Blade Holder soild on the third go round on and off. I'm waiting for the penatrating oil to work it's way through and hope to continue afterward. I did some damage to the grenade section so I've got more filing and sanding to do now. *sigh*

[Noyl Wendor]

Wow, that is really taking shape, I really like the style you have going on this one
Do lots of pics when you are done
Very nice work.

[Boj-Vaati Mau]

Thank you, Noyl. I'll do a minimum of 3 at the end and a bunch in process. I have the shroud work done, minus the Blade Retention Screw hole (Doh!), and will bake it in a couple of days. I decided to paint the brass Activation Switch Bezel copper...







With a little bit of Fotoshop Force it looks thusly...

[Nichos Seastrider]

So seeing it colored now, I really like how the pommel piece actually looks more like a full cap. Definitely digging the contrast between the green vinyl and the copper as well.