The original plan for this build did NOT have a choke. It was added solely for internal space (the 5w resistor is Huge!).
In a 1.15"ID part, you have just under 1.04" area (if you were to look at the part from the threaded end).
The JST connectors are not that "wide & high" (.255"x.157") BUT, they are LONG (.94").
I tried (and failed) to cram a recharge port, 16mm short switch (which will take up quite a bit of space @ .627"w x .67" deep in the hilt, takes up .42" of your 1.04"), a 5mm led, 6 JST connectors, a power extender, a dynaohm resistor and the 2.2ohm 5w beast of a resistor, and ALL the wire (26g) into a 4" double fluted extension. Now I had some space in the ribbed section with the battery, but I lost that with the male end of the choke (or originally, Blade holder).
I'm sure with more experience, and a bit more trial and error (I WAS pressed for time), I could have planned it out better (and got a smaller resistor) to reduce space needed. I guess that is what "upgrades" and tinkering later is for!
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