So last semester I took a robotics course at my local college and one of the assignments was dealing with lights, I decided to make a lightsaber (arduino powered) out of plumbing parts. Unfortunately it was fragile enough that if I hit it on anything it would likely blow apart... So this semester (in addition to my normal classes) I took the machining course, which afforded me the opportunity to make an improved design. I looked around and came across the lightsaber design of Rahm Kota (The Force Unleashed) made by Roland Palotai and liked it so much I modeled mine after it with a slightly different style.
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I started with a 3D render and then a printed model (to judge size), then took a solid 1.75" round of aluminum and went at it.
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I wanted to use the TCSS body (6") so I machined my emitter and pommel to match.
Continued...
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