the reality of it is.. its really up to the builder/owner.
myself.. I use 12" as a BASE rule of thumb... (most things come out to that or close).. and it looks & feels good, well balance both physically and visually (to me)..
so depending on the 'design' a build could be slightly bigger I think I had one 13" (or very close).. or slightly under..
but also keep in mind..if you ever plan on selling them.. you need to design/build for the masses as well..
Personally I think even 14" is a little big. The Force FX sabers are generally 11" if that matters at all to you. I generally stay between 11-13" when I'm planning with the MHS builder. Imagine the saber on your belt (especially since you mentioned that it would be a costume saber). You don't want it to awkwardly hang or for that matter stick up (depending on where your Covertec is placed). Just my two cents. Good luck with your build. And...careful not to twist your wires or make them too long! I learned that the hard way....
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