Need advice on switch placement (2 momentary switches) on this saber design

[Darth Obi Don]

Also when you drill and tap the .75 extension use a short AV switch with a tall bezel to give you the most working room inside.

[Forgetful Jedi Knight]

Once you screw the .75 extension to the choke you should be able to drill and tap it for an AV switch. Just don't plan on taking it apart again afterwards because it probably won't line up right again. Put your second AV switch in the hilt using insert part 10 http://www.thecustomsabershop.com/MP...e-10-P526.aspx
Or 11 http://www.thecustomsabershop.com/MP...e-11-P527.aspx

Those are meant for pommel parts, Also trying to do an AV switch in a .75" extension will mean cutting through the threads. There is only about 1/4" of unthreaded space in one of those pieces.

[Darth Obi Don]

I meant to cut through the threads. Once the extension and the choke are screwed together just treat it like it's one solid piece of metal. You should still be able to drill and tap it for an AV switch. As to the pommel , put the power switch in the pommel and the auxiliary switch in the .75 extension .

[Silver Serpent]

If you want those two pieces permanently locked together so you can drill and tap in the threads, I recommend using a threadlocker compound on them first. Loctite Red is permanent. Loctite Blue is not, but it won't back out under normal circumstances.

[Darth Obi Don]

I was thinking J B Weld to lock them together. You could also use this part, http://www.thecustomsabershop.com/MH...ring-P897.aspx And use tactile switches instead of the AV style.

[Darth Kenobi]

Hi there -

I'm new to the forum and this would be my first custom build. I really like the idea of using the long choke on a 12 inch saber (see the attached jpg). Given the general lack of real estate for switches, I'd really like some advice on where to put the primary and secondary momentary switches on this design.
Attachment 9369
My first idea was whether TCSS could machine the primary switch hole in the base of the choke -right above the threads near the middle of the saber. I'd prefer a full sized secondary switch, but I may need to settle for something smaller mounted in the mara jade extension. That is unless I can put another switch hole in the 3/4" inch extension, but that would involve drilling through the threads between adjacent sections.

Any suggestions?

Thanks in advance.

Shady Canuck

You could do a switch in the pommel using these
Guarded switch http://www.thecustomsabershop.com/Po...le-1-P425.aspx
Av switch http://www.thecustomsabershop.com/Po...le-2-P476.aspx
You could drill holes in those too for sound or do reverse sound
And for your second switch you could put a switch in a covertec knob somehow

[MontyBMan]

I'm going to be attempting something similar with two momentary switches and possibly drilling and tapping through a threaded section, that's a few months ahead though. the design I'm working with is what I posted here. Going to have to fit a PC v3.5 and a 7.4v Li-ion 800mAh 14500 Battery Pack in the hilt with a speaker mount v5 (which adds .75" to the internals). I plan on having the R.I.C.E. port and the recharge port in the pommel so the speaker needs to be locked inside the body. Saber Build Basic.JPG