Building your own Blade = Pain in the ...

[bigkevin61]

So, I'm working on a special project (I will be doing a full posting on this subject, when complete a few weeks into September), and out of monetary constraints, I am forced to make my own Blade(s), as opposed to purchasing pre-built (as all of mine have been so far). Due to monetary and time constraints, I cannot order different tube/parts/film to try.

In researching and buying parts for my own saber over a year ago now, and actually building my son's saber last winter, I avoided the "build your own blade" part, as I expected it to be the most difficult part of the building process.

In this current project, I'm finding that assumption to be true.

Yes, I read Tutorials (I think Jay-gon Jinn's is the best), but the skill/art of blade making using the clear cellophane wrap is kicking my ...

I'm using 1" thin walled clear tube (32" length), and getting the ~4.5' of cellophane on the 5/8ths dowel and into the tube works fine. The trouble begins when trying to "unwrap" the cellophane inside the tube (to get it against the ID of the PolyC tube).
My first attempt, I just slid the dowel out, hopping a bit of vibrations (tapping) would allow the cellophane to unravel, and match the ID of the tube. NO amount of coercion worked, and I had a ~5/8th cellophane tube within a 1" thin walled PolyC tube. Less than ideal.
My next attempt I stuck a really tiny bit of tape at one end (the cellophane is 40" wide), and tried to unroll it. it becomes REALLY difficult to tell if you are actually doing anything. Once I thought I was done, I cut the end with the tape off the dowel rod, and slid it out. Well, the insides were all gobbledygook, as I apparently had no idea I unwound enough.
My third attempt was actually a test with a 18.5" PolyC Tube cutoff I had. I "frosted" it with 220 grit, with a buff of 400 grit after. No cellophane inside. This on it's own looks pretty darn good. I'm not sure how it would look on its own, on a full length blade.
image.jpg image.jpg (different exposures)

My attempts (and frustration) mirror Kategora's.

Without the ability to buy different materials, OR a completed blade, I only see three possibilities:
1) Frost the 32" PolyC tube and hope that is enough.
2) Frost the 32" PolyC tube, and try only a SMALL (2') amount of cellophane (and IF that works, do more as needed a bit at a time)
3) Forgo the Frost, and just keep banging on it. Either at a full 4.5-5', or in smaller increments.

Any advice or sympathy would be appreciated.