I would like to see some examples of chassis that others have designed for their sabers. In the interests of that, here is a description of my chassis and an image.
Here is an image of my lightsaber chassis. My saber is very basic, so the chassis is simply a 4 x AA battery holder and a 1000mA buckpuck. The wires have been hot glued to the battery holder to keep them still. There are only five lines involved:
1) Battery (-) to Buckpuck (-) (This is soldered and then insulated by shrink tubing which is glued down to the battery holder.)
2) Battery (+) to Latching Switch
3) Latching Switch to Buckpuck (+)
4) LED (+) to Buckpuck LED (+)
5) LED (-) to Buckpuck LED (-)
Lines two through five are brought to a connector ( http://www.thecustomsabershop.com/4-...ctor-P457.aspx ). This is my chassis:
Buckpuck Chassis.jpg
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