I thought I'd give this saber it's own thread.
It will be a very accurate Qui-Gon Jinn replica, with a green K2, Erv's CF 2.5, and rechargeable battery. Here are some shots from the process.
Masking taped a polished aluminum pipe and measured out the dimensions. the cut with a dremmel and mitre saw.
Used a secure jig and a router to carve out the flat part of the grip. The grip section is acetal plastic (delrin).
Again with the jig and router to make the grooves.
Machine the pomel - preped for a speaker, and the cover plate for where Erv's Buttered toast will go.
Most of the parts machined
Painting started.
I'm just waiting for a package from France, and my rechargeable batteries to arrive.
MC
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