bulding 1.25 sink tube saber. (build log)

[mrknify]

1x 6" sink tube flanged
1x 5.5"x 1.25" aircraft grade aluminum tubing

holes present in tubing for an machine gun air cooler (from airsoft mod)

first thing i did was sand the tubing using a drill with a small cloth over the drill bit. this held the aluminum tube, I used a random screw twisted into the cloth through one of the holes to give the tube an anchor point. 400 grit (ish maybe 360...) sanded checking for fit with the sink tube, took about 20 minutes ish.
IMG_20120711_172802.jpg
next step took a bit, I had to wait until I was at the shop, to talk to one of the machinists. I had the MHS new heatsink lip lathed down about 64 thou (0.064") this brought it to the size that then would fit inside the flange of the sink tube. I had the aluminum tube leftover from modding my airsoft gun, that I shortly after modding lost the mod, so I remade it again... not gonna happen again.
IMG_20120712_232157.jpgthis image is before the modification to the led heatsink.

Now, I have been playing with my leather and coming up with various different grips, and ways to attach the hilt together.
What I want is a mechanical latch, I just need to come up with a better way to secure the blade, right now i'm wrapping it with leather but it makes it a pain to remove and replace.

The blade is 22.40" approx its a cut down from the 2010 Hasbro Ultimate FX, until I can get some polycarbonate, as they are the same OD (outside diameter)

I am looking into finding something that has a ID (inside diameter) of 1" (blade od) that I can put on the top of my aluminum tube to secure the blade, I would also be fastening this to the tube.

until next time.


(edit to blade outside diameter from 7/8 to 1" thanks to
Crystal Chambers )

[mrknify]

with a little canniblization of my "problem" saber,I now move onto modding a hasbro 2009 vader pcb.


IMG_20120715_231203.jpgIMG_20120715_231221.jpg

[Silver Serpent]

Looks like a decent saber. It kinda reminds me of a Looftlighter...

http://www.looftlighter.com/

[Crystal Chambers]

Seems like a lot of work when you can just order a sink tube blade holder from the store here. They are for 1"blades though.

[mrknify]

Seems like a lot of work when you can just order a sink tube blade holder from the store here. They are for 1"blades though.

thanks, i put the wrong measurement down the blade is 1" od.

the blade holder, would be great if I was just using the sinktube, but I'm using an aluminum do-hickey on it alse

[mrknify]

IMG_20120811_094406.jpgIMG_20120811_094716.jpg

before and after the lines come off.

Silver serpent, the mesh does add a nice touch gives me an idea for a blaster.... mmmm high tech.

[mrknify]

Looks like a decent saber. It kinda reminds me of a Looftlighter...

http://www.looftlighter.com/

thats awesome
, i want one!
as for the sink tube extension, that means waiting a month, and kinda defeats the build concept.

[mrknify]

some more work done, I have , tapped a new hole, with no help from rona, i guess they really don't know how to do it right... metric taps, but no metric drill bits... i'm still angry about the run around they gave me.

ok back to the cool stuff.

blade retention hole drilled and tapped 6-32, with a # 36 drillbit.

hilt body painted flat black.

2012-08-07 19.24.37.jpghate using my tablet on this forum..... ok 2nd base coat done, next is "rust" then gold/brass/tan color.
i've painted it with my nice brass bladeholder in, i've got somthing up my sleeve for that....

ah yes a nice first coat.this will do nicely.....

[mrknify]

oops, broke a brass screw. in a counter-sunk hole..... oops. not gotta drill it out... it can stay. now to find somthing to cover the ugly hole....

issues with electronics.... i really need to stop experimenting with junk and get some real parts...

2012-06-28 12.41.12-1 (2).jpg

[Crystal Chambers]

"junk"can be neat to work with and very one of a kind. The only problem is if you want to repeat or replace a botched part it might not be easy to find when you're scavaging.