First Build - Denique

[bambua]

After a year or so of lurking and reading and learning I've taken the plunge and ordered what I need for my first saber! I was actually ready to do it a few weeks ago but the Crystal Focus boards were out at the time but now they are back in stock so it's time to start!

This is my basic design:

Initial Saber Plan.jpg

I planning on adding some more bits once they get back in stock as well as doing some 3d printing / painting for detail work. I did the internal modeling to get my spacing, it's going to be tight but I think I can pull it off. If not I may have to make an extension for it, but only in the 1-1.5 inch range. I'll see once I do a mockup of the parts after they get in, I'm pretty handing with 3d modeling as well as metal lathe/millwork so coming up with a solution should be fun.

Also going to be in it:

CF 7.5
tri cree RGRB
7.4v 18500 pack
recharge port on the pommel
misc chassis parts

I'll post more pictures / plan once the parts start arriving!

- Bambua

[Generic Jedi]

Good luck with your build, and don't forget the speaker.

[bambua]

Good luck with your build, and don't forget the speaker.

Thanks, and don't worry it's in there! I just didn't put it in the list hehe.

[Darth Nater]

Keep in mind the length of your battery solution and where your switch hangs down. And advice up front, if you have a way of using a double 18500/18650 as opposed to a side by side 14500/14650... do it. My 14500 pack is all that will fit in mine due the length restrictions, and its runtime while never stellar has dropped to the point that I need a new pack 3 years later. My kids sabers that run on single 18500 packs last a long time.

[bambua]

Keep in mind the length of your battery solution and where your switch hangs down. And advice up front, if you have a way of using a double 18500/18650 as opposed to a side by side 14500/14650... do it. My 14500 pack is all that will fit in mine due the length restrictions, and its runtime while never stellar has dropped to the point that I need a new pack 3 years later. My kids sabers that run on single 18500 packs last a long time.

I will definitely keep that in mind as I mock it up. I have a couple extensions coming as well and will see how everything is going to fit. I'm planing on going either 18500 or 18650. I have a couple of each around and can play with the fit.

Thanks!

[bambua]

That exciting feeling when you know your saber parts are out for delivery, that sad feeling when you remember USPS doesn't show up for another 4 hours. GAH!

[bambua]

Parts have arrived, dry fit done, tested wiring diagram and activated the board and it all worked! Will post some pictures as I start the final build.

From the dry fit I have a pretty good idea where I am going to have fit issues and where I have room to hide wire/connectors.

The chassis and soldering wire leads are up first wish me luck!

[bambua]

First couple 3D printed parts are designed and off to be printed, trying it a few different ways and materials to see what works best.

Kill Key:
Kill Key.jpg

Plan is to print this in black, and do some metallic weathering so that it fits in with the aluminum on the saber.

Decorative Ring:
Spacer.jpg

Plan on this is to do a couple prints, first in black and just do some edge highlights with metallic to make it look weathered. Second plan is a print without the screws in it but holes, and then put actual screws into them. Should have the prints in about a week to give them a test will post pictures as soon as they arrive along with a test fit of the full saber.

- Bambua

[bambua]

So while I wait for the 3D printed parts to arrive I started wiring up my components. For each of them I let plenty of extra wire so I can trim it down to size as I fit it all to the chassis and on to the plugs I'm using.

All of the parts:


Here is the LED as it's wired, assembled and inserted in the blade holder:





Here are the switches, LED and speaker wired:


Next up wiring up the CF and the CEX after test fitting the chassis...

[bambua]

First off, first round of 3D prints will be here tomorrow, so excited! Second, I spent the morning designing my chassis now that I've mocked everything up. I used the TCSS chassis pieces for some dimensions and to mock it up and came up with this:

This is a top iso shot of it with the Speaker and connection rods through it, it has a spot for the Crystal Focus 7.5 and a CEX with a battery on the bottom:


Bottom iso shot with the speaker and connection rods:


Top iso shot without boards or speaker holder:


Hopefully this will work out! It's exciting to finally be getting these pieces I've been planning on and see how they are all working together.

- Bambua