Hasid
If that center section is wood, you might want to consider how you intend on attaching it to the rest of the saber. I imagine having the brass piece plug down into the wood would be the best. I'm not realy sure how strong it will be though. I assume it would be hollow to allow for electronics. That would weaken it even more.
Have you considered a wood laminate? It wouldn't be as nice as real wood, but they make some pretty nice sheets of self adhesive laminates that have wood like grain and patterns. You'd have a seam on it though where the two edges meet.
Take a 1.25" sink tube and wrap the wood laminate over it. This would be your center section. You could then use a 1.5" sink tube adapter on the front and rear of the 1.25" sink tube. I know that sounds wrong, but the INTERIOR of the 1.5" sink tube adapter will fit a 1.25" sink tube. You can then screw in the blade holder, which I imagine you'd have to get custom machined or at least altered.
I'm not sure about having the parts made in brass, though I know there are places that can brass plate things for you. I have a section of aluminum fluted tubing that was brass plated.
My solution for your design isn't perfect, but it's something to think about.
Corbin
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