'Dies Justitia' Design and build log

[Jagahati]

Looks like I just lucked out. With the Box there is enough room between them when mounted vertically. If it gets too close the soldering lugs could be trimmed down (wouldn't be the first time).

Currently thinking that a Graflex glass eye would make a pretty sick looking kill plug!

Thanks again for your help Quixotic Jedi!

[Forgetful Jedi Knight]

What about the threading between those two parts (blade holder and ribbed section)?

[solaren]

First: Love the design, very similar to one I almost started to make.

What about the threading between those two parts (blade holder and ribbed section)?

Also pretty sure that layout has those two parts meeting in the middle of the LED/heatsink.

[Jagahati]

Also pretty sure that has those two parts meeting in the middle of your LED/heatsink.

I have two different models built one for outside with internals just kinda fudged in, if you look at the cut-a-way view there is space between heat sink holder and the top of the crystal chamber. Yeah by that model it wouldn't work.

FJK is also correct, threads will be drilled though, and yeah that is dicey and will require that the box and charge port be removed to unscrew those two sections. To make the drilling less problematic a set screw will be drilled first to lock the two pieces in place before i drill the larger holes. The set screw should be easy enough to hide under the shroud.

[Forgetful Jedi Knight]

FJK is also correct, threads will be drilled though, and yeah that is dicey and will require that the box and charge port be removed to unscrew those two sections. To make the drilling less problematic a set screw will be drilled first to lock the two pieces in place before i drill the larger holes. The set screw should be easy enough to hide under the shroud.

if you are going through the threaded parts (which is a bad idea), you will also be going through the heat sink assembly (which WON'T work).

[Noyl Wendor]

May work if you got an extension like this http://www.thecustomsabershop.com/75...sion-P776.aspx and mounted your box just as in the above pic. You may have to move a couple pieces down and make your shroud on the box side a bit longer. You would narrowly avoid the heat sink.
But FJK is right, drilling through threads is a tricky thing to do. Small holes okay, but big enough for all the internals in that box. I'm not really sure. If you do pull it off show the pics
But give it a second thought before you turn on your drill

[sgcdialler]

I'm relatively sure that that piece is part of his original design, Noyl. I hate to sound like a parrot here, but FJK is right. That layout has a switch attempting to occupy the same space as the heatsink itself, regardless of whether or not you avoid the heatsink housing.

I would suggest bumping from the .75" extension under the emitter to a 2" extension. This will give you a little more room to play without completely ruining the overall proportions of the saber. In these renders I replaced the 4" lower extension with the MHS blank 1 extension (3.7") to get the male and female threads. You could use a thread changer if you stay with the 4" double female though.

Of course drilling through threads is tricky. Drilling through threads and a heatsink though... well let's just say that's not a life you want. :P

SaberBuilder_rende_internal.jpgSaberBuilder_render.jpg

[Jagahati]

Thanks for the feedback guys! Here is a more accurate model of what the parts inside should look like. Gonna need parts in hand to verify for sure if this will work or not.


Also took a couple of pics of my shop and my first ever MHS compatible threads cut!


Threads are ugly as heck, need to adjust the angle of my compound and use some cutting fluid next time. They did thread smoothly when fitted to a MHS part and cinched tightly at the end. Plan to try internal threads soon, but the rest of my week is already over-booked may not get any saber-ing in.

[Quixotic Jedi]

You set your compound to half the angle of your threads. So for a V thread which is 60 degrees, you set your compound to 30 degrees. Once you set your tool till it just touches your work, you mark that on your cross slide and that is where you return for all your repeat cuts. You use your compound for your infeed until you reach final depth of thread.

Oh, and for safety's sake you never leave the chuck wrench in the chuck. They can, and will, fly out and hurt you!

[Jagahati]

Oh, and for safety's sake you never leave the chuck wrench in the chuck. They can, and will, fly out and hurt you!

Yeah bad habit, good news for me is that the safety shield won't close with the wrench in and my chuck sits too close to the ways to fit on the underside either. I do have the habit of hand-spinning the chuck before firing up the motor to make sure my feed is either engaged or disengaged as it should be, so that exaserbates my bad habit with the wrench.

You are right about the compound, I had mistakenly set it as if I were cutting a square type thread (read all directions dummy) and realized my mistake the first time I carved up my pretty threads on the next pass.

Thanks for the response.