Been a while since I've been here

[Nineteen]

So I decided I want to redo the lightsaber I made a few years ago before the new movie comes out. I have experience in building, but a lot of things have changed, so some clarity of some subjects would be welcome. First, my hardware list:
-1.5" sink tube
-End cap
-Blade safety plug/blade
-Recharge port kill plug
-Covertech belt clip
-1.5" to MHS adapter
-MHSV1 Blade Holder Style 25

My first question is on the blade holder. Is it possible to order custom lathe work to sort of reshape the blade holder so it's the same OD as the MHS adapter? I'd like to customize the end of the tube, and then put the blade holder inside it for a sort of stylized look, like so: http://puu.sh/bg1xu.png

Now the wiring, and of course, this is where it gets sticky. I'd like to use the Nano Biscotte, so let's use that as a base to work from.
-Nano Biscotte sound board
-NB Wiring Harness: http://www.thecustomsabershop.com/NB...ness-P961.aspx
-Speaker and female JST connector for speaker
-Rebel Star LED and MHS heatsink module: http://www.thecustomsabershop.com/Re...dule-P653.aspx
-Li-ion battery with JST connector: http://www.thecustomsabershop.com/Li...dule-P672.aspx
-MWS recharge port: http://www.thecustomsabershop.com/MW...Port-P877.aspx
-Li-ion charger

Okay, time for the fun questions.
1. For the wiring harness for the Nano Biscotte board, what are all the connectors for? Going from top to bottom, numbered 1 to 4 and the "hanging" wire. Obviously 4 is the speaker, but what about the others?
2. Could there possibly be a diagram for the wiring I want? I think it's clear the kind of setup I want, and believe it's pretty standard. I'm not sure what I should plug into what.
3. I didn't include a switch because I'm not sure what I need. I like the look of anti vandal switches, but I'm not sure how to mount them, or if it's even possible to mount them, on a sink tube.
4. Any resistors needed? Any parts I'm missing?

I apologize if any of these questions have been answered many times before. I tried to find resources on how the modular wiring system works, but couldn't find any.

[Forgetful Jedi Knight]

See my replies in yellow:

So I decided I want to redo the lightsaber I made a few years ago before the new movie comes out. I have experience in building, but a lot of things have changed, so some clarity of some subjects would be welcome. First, my hardware list:
-1.5" sink tube
-End cap
-Blade safety plug/blade
-Recharge port kill plug
-Covertech belt clip
-1.5" to MHS adapter
-MHSV1 Blade Holder Style 25

My first question is on the blade holder. Is it possible to order custom lathe work to sort of reshape the blade holder so it's the same OD as the MHS adapter? I'd like to customize the end of the tube, and then put the blade holder inside it for a sort of stylized look, like so: http://puu.sh/bg1xu.png

You would need to talk to Tim.

Now the wiring, and of course, this is where it gets sticky. I'd like to use the Nano Biscotte, so let's use that as a base to work from.
-Nano Biscotte sound board
-NB Wiring Harness: http://www.thecustomsabershop.com/NB...ness-P961.aspx
-Speaker and female JST connector for speaker
-Rebel Star LED and MHS heatsink module: http://www.thecustomsabershop.com/Re...dule-P653.aspx
-Li-ion battery with JST connector: http://www.thecustomsabershop.com/Li...dule-P672.aspx
-MWS recharge port: http://www.thecustomsabershop.com/MW...Port-P877.aspx
-Li-ion charger

Okay, time for the fun questions.
1. For the wiring harness for the Nano Biscotte board, what are all the connectors for? Going from top to bottom, numbered 1 to 4 and the "hanging" wire. Obviously 4 is the speaker, but what about the others?

It's in the manual (located in the description in the store)

2. Could there possibly be a diagram for the wiring I want? I think it's clear the kind of setup I want, and believe it's pretty standard. I'm not sure what I should plug into what.

Yes, there is a section for the board and I posted diagrams there. Look in Saber Sound, you'll find them there if you look around.

3. I didn't include a switch because I'm not sure what I need. I like the look of anti vandal switches, but I'm not sure how to mount them, or if it's even possible to mount them, on a sink tube.

You need a momentary switch of some type. The rest is up to you.

4. Any resistors needed? Any parts I'm missing?

You will likely need a resistor the the main LED, and for the LED int he resistor if you go that route.

I apologize if any of these questions have been answered many times before. I tried to find resources on how the modular wiring system works, but couldn't find any.

[Nineteen]

What I mean with the switch is, how do I actually mount the thing on the tube? The last time I made a lightsaber, it was hard to actually get in the tube and hold nuts in place while I put in screws. I can't imagine trying to screw in a nut on the inside.

[Forgetful Jedi Knight]

If you're using a sink tube, that's what you would need to do.

[Nineteen]

I can't find the explanation of what the NB wiring harness pieces are. I'm talking about this: http://www.thecustomsabershop.com/NB...ness-P961.aspx

The description of those connections are not in the NB manual, and I can't tell where some of the wires go in the picture.

[Forgetful Jedi Knight]

The description of what those connections go to are in the boards description in the store AND on PAGE 6 of the manual. You amy want to re-read the manual again.

[Nineteen]

This is Page 6. http://puu.sh/bgfM1.jpg

That does not describe this: http://puu.sh/bgfNu.jpg

What are the four plugs and the hanging wire? I can't tell from the picture where all of the wires go.

[Forgetful Jedi Knight]

This is Page 6. http://puu.sh/bgfM1.jpg

That does not describe this: http://puu.sh/bgfNu.jpg

What are the four plugs and the hanging wire? I can't tell from the picture where all of the wires go.

Uh yeah, they do, if you start from the top (Red and white wire), they tell you what is what. I'll give you a hand, the hanging wire is the FoC wire. I got that because I read what I gave you to read. One is a battery, one is a switch, one is a LED and one is a speaker.

[Nineteen]

Uh yeah, they do, if you start from the top (Red and white wire), they tell you what is what. I'll give you a hand, the hanging wire is the FoC wire. I got that because I read what I gave you to read. One is a battery, one is a switch, one is a LED and one is a speaker.

Okay, so red/black connects to the battery pack, white/blue would connect to the LED module, yellow/yellow would connect to the switch somehow (how would THAT work?), and green/green is the speaker, like I said before.

Maybe I should just give up on using the Modular Wiring System. I somehow can't make the translation between wiring diagrams and the MWS connectors I'm seeing. I understand how your wiring diagram works, but I don't understand how to use MWS to achieve it.

[Forgetful Jedi Knight]

It works a lot easier if you have everything in front of you. You figured them out.