So currently I am designing a saber inspired by Darth Revans using MHSv1 parts. While planning the build I've been modeling each part in CAD to make sure everything will fit correctly when I recieve them....

Revan Saber Exterior.jpg

REVAN CHASSIS.jpg

REVAN MHS BUILDER_EXPLODED.jpg



Everything looked good up until I realized my obi-wan style pommel #4 (POM4) will not fit with my current chassis design.
(This pommel: http://www.thecustomsabershop.com/Po...e-4-P1071.aspx )

My chassis relies on the custom saber shops metal chassis disk to retain itself inbetween the male threading of the pommel and the female threading of the 3in extension near the bottom. Pommel style 4 apparently does not fit speaker mounts as far inside of it as other pommels do, due to its skinny choke point. Heres a cross section thru the hilt for reference of what I mean:

Speaker Mount- Pommel Crash.jpg


Any suggestions on what I can do to fix this? what other chassis retention methods can be used in this situation??

I DO have enough room to move the chassis farther up in the hilt a bit, but how would I retain it?