Advice on building Darth Revan Hilt?

[Kilryth]

I'm building two Darth Revan hilts from KOTOR. I attached a reference image at the bottom. Does anyone have recommendations on how to build this? I prefer that it be as solid as possible (for lightsaber dueling), so I prefer that it all be metal.

I've found some similar style parts, but nothing exact: the MPS Style 3 v1 and V2 pommels, the Style 16 and 18 Emitters, Style 1 body, MHS Blank Style 1-3 Extensions, and Adapters: 1.2" double female, double ended male style 1, 0.75" Male/Female ext, Double Male Ext (1.5"), and 2-10" double female threaded Ext.

Looks like a lot of this will need to be custom cut from sink tubes o-rings, etc. I know LDM worked on something in the past, but I'm having trouble getting ahold of him.

Thank you!

PC120048.jpg

[Silver Serpent]

That's an Obi-Wan TPM pommel. More commonly referred to as an "Acerocket pommel", since that's the name of the machinist who builds them. You can occasionally find them for sale over on the FX-sabers forums. They are MHS compatible.

Most of the other pieces are easily done with stock or slightly modified MHS parts.

MHS based sabers are generally rock-solid for dueling. If you want it to be super accurate to the game, then you will likely need a metal lathe, or know a machinist with one.

[Kilryth]

Thank you Silver Serpent!

As for modifying the other parts, do you recommend dremeling down parts or using sink tubes to layer on top of the parts? If dremeling, what's the best way of obtaining a uniform finish. Sanding a smooth circle is one of the harder things to do with a dremel. I can get close, but it's still rough.

Thanks!

[Silver Serpent]

If you don't have a lathe, you're gonna need to whip up a jig of some sort. Something to hold your part securely and still allow it to rotate, and then something to rest your dremel against so it remains steady.

If you're just cutting lines in your parts, the dremel is probably fine. Maybe score a line with a pipe cutter first, or a sharpie... something to give you a guide so you can stay where you want.

I'd also do some test pieces first on scrap material. PVC is inexpensive from the hardware store. You should be able to test your jig out on PVC and get your technique down before moving on to the more expensive MHS parts.

[Kilryth]

Do you know if the basic $130 Harbor Freight Wood Working lathe will work?

[Silver Serpent]

I don't know. I'm not a machinist, and I have no idea if there are any specific safety concerns with using a wood lathe for metalwork.

I have seen people creating a super-budget lathe using a hand drill before. Again, there are probably some safety issues involved.

[jin starkiller]

The answer is no you cannot use a wood working lathe on metal it is not setup for it and then there is the safety issue of trying to use it on metal

[Forgetful Jedi Knight]

Do you know if the basic $130 Harbor Freight Wood Working lathe will work?

For metal? No.

[Kilryth]

Thank you all. I thought that the wood working lathe might be ok on a slow rotating motion and using a dremel. Having never used a lathe, I don't know the slowest it can go though. Was worth considering; thanks all.

Looks like I'll be trying to build this saber from MHS parts and hardware store / homemade parts. Found a few similar MHS parts that should get me there mostly