Results 1 to 5 of 5

Thread: Custom Hilt, reveal chassis, cf9 w/ cex build

  1. #1

    Default Custom Hilt, reveal chassis, cf9 w/ cex build

    This is one of the more involved commissions I've been given the honor of building. The trick to this one will be space management, I like to make all my hilts as slim as possible, most falling just over 1.25" in OD, this makes fitting intricate chassis a challenge. Especially when the client requests a fully loaded CFv9 w/ CEX and no single cell hack....We will see how this goes!



    Here is the design sketch that was approved by my client, the size is not to scale, but it gives an overall layout of how it will go together.





    I approached this one a bit backwards and started with the shrouds. These will still receive a fair amount of filing and sanding to get everything straight and perfect. They were cut from 1.25" copper tubing using the trusty dremel.



    Found some good cutoff spare pieces of aluminum to use for the main hilt...let the machining commence. I use a Grizzly G0516 Lathe/Mill Combo. Overall the machine works well, its the first heavy machine i've ever purchased, if I had it to do again I would buy the lathe and mill seperately, the lathe is hampered by having the mill attached but I find most milling jobs to be hindered by the limited workspace.








    Both halves came out really nice and the shrouds fit perfectly snug without marring the finish of the aluminum. Next will be only my second attempt at threading so fingers crossed I don't ruin these beautiful pieces lol. I will practice on scrap until i have the whole process down.

    After the threads are done, I'll be boring out the bottom half a bit more to help accommodate the batter and board being sandwiched to help maintain space. All the main electronics will be housed in the lower half to allow for the top to be an intricate crystal chamber.

    Finally the main hilt pieces will have windows milled for the various reveals and finally the chassis work will begin.

    Thanks for looking!
    Last edited by Darth Leximus; 07-10-2018 at 10:02 AM.
    wsoFB by Nathan Barnes, on Flickr

  2. #2

    Default

    You've done it again! Really nice design. Excuses me for asking, but how are you going to make the threading?

  3. #3

    Default

    Quote Originally Posted by Seth Skywalker View Post
    You've done it again! Really nice design. Excuses me for asking, but how are you going to make the threading?
    The threading will be cut on the lathe
    wsoFB by Nathan Barnes, on Flickr

  4. #4

    Default

    I love those copper shrouds! Are you hand cutting them? That's a lot of work. Very nice. PS, this is a distraction from your personal build! I love the layered different metals look.

    "Let the past die."

  5. #5

    Default

    Quote Originally Posted by Tom Tilmon View Post
    I love those copper shrouds! Are you hand cutting them? That's a lot of work. Very nice. PS, this is a distraction from your personal build! I love the layered different metals look.
    Thanks! Yes I hand cut all the shrouds. My personal build is a spare time thing, I do about an hour of work on it every couple of days lol. I have 5 full custom commissions and another 5 sabers I'm altering or adding too in one way or another. This is why I don't have a saber of my own, I always feel like I'm stealing time away from other people's builds when I'm working on my own.
    wsoFB by Nathan Barnes, on Flickr

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •