Here is a saber I made for my nephew for Christmas. I am making my brother (his dad) a saber as well and will post pics of it once it is completed.
The internals include a green Lux 1 driven by a 350ma micro puck, Hasbro sound board from a 3v Mace Windu saber as seen here.
I used a 4.8v in hilt recharge system utilizing Ni Mh AAA cells. To insure that the board and micro puck did not get too much voltage i used a LM317T adjustable voltage regulator to insure that the board and micro puck only got 3.5 volts.
The grip was made using slip washers and heat shrink tubing (Thanks for the idea DarthHideous) with screws, the switch and the recharge port securing it in place.
The blade will be re-done once I get more celo-wrap it is a thin walled 28 inch blade with the diffuser sold here in the shop. It needs about 4 feet of celophane in it to properly light the entire blade.
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