Inspired by the new MHS blade holder, I made a hilt based roughly on the first saber you get in the Old Republic game, and which our own sloth furnace had a hand in bringing to life. I've always felt those sabers were designed with exaggerated parts in order to make them look distinctive on the small screen, so I decided to forgo the massive red button and use a standard activation box with a lighted anti-vandal switch. But the leather is real. I used a traditional method to make the grip. Soak the leather in warm water for 20 minutes, pat off the extra water with a towel, apply ordinary glue where it's needed, then tightly wrap the whole thing with string and let it dry overnight. (I put double-sided tape on the aluminum hilt in order for the leather to have something to hang on to.) The string leaves a permanent pattern on the leather. I then applied beeswax to the leather. (Here's a demonstration by a traditional sword maker for anyone who's interested: http://www.yeoldegaffers.com/project_grip_2.asp)
From the beginning, I was thinking about weathering this. It's an Old Republic saber, after all. Also, it's hard to give an MHS hilt a distinctive look without doing something to it. But I have never weather a saber before, and frankly it goes against my somewhat anal retentive nature. The idea of taking a perfectly good hilt and tossing it down a stony hill is pretty horrifying. But I think it's probably the best thing for this hilt.
I don't want to overdo it, though. I want to make it seem like an old but well-cared for saber. I am literally thinking of rolling it down a stony hill a couple of times, as well as using a dremel with a metal brush to soften the edges, and then using Birchwood Casey Aluminum Black in the crevices and lightly polishing the surfaces that would get a lot of handling.
Anyway, here's the "Before." The top image is after I removed the string, the second is after I applied the beeswax. Obviously, there are no electronics in the hilt yet (unless you count the switches). I'll put the electronics in after weathering.
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