Hi, I am new the saber building community and subsequently new to TCSS forums. I am currently in the process of getting started on my first ever saber build. I have ordered quite a few MHS V1 Hilt parts, and Tim has been gracious enough to custom mill a few other MHS V1 Hilt parts for me in order to build my saber. As I am currently awaiting those to arrive, I am stuck in a bit of analysis paralysis around one aspect of my chassis design and was hoping I could get a little guidance (I did search on this topic prior to posting...so my apologies if I missed an obvious answer).

Attached is an image of a rough approximation of the back of my Hilt design. It is not exact, but close enough. I am using Pommel 10, a 4inch double female extension, and then MHS Ribbed Extension Style 2 (MHS Ribbed Extension pictured). My issue is this, the ID of the Ribbed Extension and the Pommel are both 1.15", where as he ID of the 4" double female is 1.25". I plan to have the chassis and speaker span from the pommel through at least a portion of the ribbed extension, but I'm not certain if it makes sense to build the entire chassis with components the are 1.14" OD (either TCSS Chassis Discs, Goth-3D or ShtokCustomWorx) of if I should try to make parts of the Chassis 1.24" OD? If I were to make the chassis only 1.14" OD, would I run into any potential issues or run the risk of damaging my saber since there would be "air space" around part of the chassis that is not secured for the 4" stretch?

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Thanks in advance for any advice?
Rich