I posted it on F/X-Sabers' forums, and thought I'd share this with you guys, too!
Since I finished converting my son's RLSA to an F/X type saber, I had some time to start on another project I've been wanting to do; converting my blue bladed EL RLSA saber to a Luxeon with F/X!
This saber started out as a simple EL saber with no sound:
It wasn't very bright, so I decided to convert it to a Luxeon saber with F/X sound! I took it apart and got started:
Here's the blade holder. This was the first thing I had to modify:
I started out by putting it in the drill press and drilling a 7/8" hole for the optics to sit in. I then realized that there wouldn't be enough clearance for the screws on the TCSS heatsink I used to mount the led, so I went up to a 1" drill bit:
I also drilled and tapped the emitter for #4-40 threads for the mounting screws that will hold the led mount:
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