Here's a saber I recently finished up. The base is a section of 1.25" OD aluminum tubing, with a TCSS 1.25' sinktube blade holder (modified) fitted to it. LED is a Luxeon III R/O bought here at TCSS. Sound comes from an Ultrasound 2.1, and power is provided by a 4AAA battery holder bought here at TCSS.
The sculpted part of the hilt is made from a high-strength epoxy compound, that was finished by hand with various hand tools to shape it; then dyed, stained, washed and dry-brushed to give the surface finish you see.
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