I started my saber quest about 2 1/2 years ago...
After several purchases (based on product availability & budgetary needs) I had a saber that looked decent enough and worked fairly well except for a couple minor bugs. My first problem was with this: http://www.thecustomsabershop.com/MH...lder-P766.aspx
It appeared as though the battery holder part was glued to the speaker holder slightly crooked, so it would only go so far into the hilt before hitting it. I solved that by using any tool available (sandpaper, paring knife, etc) to remove the majority of the speaker holder lip on the low side, allowing the assembly to be fully inserted and (somewhat) properly seated.
One thing that bothered me after the saber was done was how the switch looked mounted with a bezel (see my sig). The seemingly random bump just seemed out of place, what with the rest of the saber being so smooth. The other issue was the 14500 battery losing contact with a spring on the battery holder during hard clashes, resulting in a total (albeit momentary) power loss for the saber.
My first upgrade idea was to buy some chassis discs, in order to secure the electronics, which I did 4 months ago (Oct. '16). The discs didn't fit in my hilt, so upgrades after that were put on hold for a while...
Next thing I did was to start going thru threads here as well as watching some of the Madcow / TCSS YouTube videos.
The general consensus was that there was a change in how hilts are made starting around July of '15.
(Mentioned around 28:43 of this video: https://www.youtube.com/watch?v=BrA-FiAvR5U and confirmed by Tim in another thread I posted not too long ago)
Anyways, a couple weeks ago I ordered a new hilt (style 4) and an activation box, with necessary mounting services. The package arrived today. As I'm going thru the bubble wrap bags, I see the new hilt, liking how shiny it is... I attach my blade holder and am really appreciating how nice a job was done with my fairly specific parts alignment request... then it hits me: "Oh crap, I forgot to order the 4-40 button head screw."
As I start assembling my chassis I run into yet another issue: even with a new hilt, the discs are still refusing to go anywhere beyond the threads. I start sanding the OD of the first nano + 18650 disc and when my arms start wearing out it just barely manages to go in, although still with a rather noticeable amount of resistance. I got a bit ahead of myself at that point and tried to just brute force the chassis into the hilt, out of frustration I guess... and wouldn't you know it, the second nano + 18650 disc snapped in half. Maybe I can superglue it back together, but that would still leave me needing to sand the living daylights out of the OD (of all 4 discs) in order to make the chassis fit. Is it possible I got a bad (oversize) set of discs? Even with the older hilt in Madcow's video (yep, linked above) his chassis discs seem to slide in far easier than anything I've experienced with either of my hilts; old (2014) & new (just delivered this morning).
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