Rathan's 1st saber - sink tube (MR Sound w/ Rebel Green)

[Rathan]

With absolutely no "Dremel-Fu" and the uttermost basic level of "Soldering-Fu" ... I have started my first saber build.

Parts:
1 - Rebel GREEN LED
1 - MR FX Anakin 2005 Sound card
1 - MHS LED Blade Holder style 3
1 - MHS to 1.5" Sink tube adapter
1 - 1.25" x 12" Joint extension tube
2 - 1.50" x 12" Sink tube
12 - 1.25" Poly washers
10 - 1.50" Poly washers
1 - Chrome faucet knob
1 - Black SPST Mom switch w/ Pololu monentary-to-latching board
1 - Green accent LED
1 - TCSS 2.1mm Charge port
1 - 4AA battery holder
5 - 8/32 Set screws
1 - 8/32 Head cap screw
1 - TCSS Machined Covertec clip button
1 - TCSS Premium speaker
1 - Rebel lens holder and 8.7degree lens
1 - 1" x 32" LED White Translucent Thin blade (added 4' cellophane)

I have added a rough render of what I hope the saber will look like.
I have also added a quick render of an easy little mod to the Covertec clip to hold my kill key. When you unclip your saber and pull the saber away from your belt, the kill key will just pull right out (depending on its location on your saber). This will activate your electronics and also keep you from losing your kill key. You could use a thin chain, nylon cord, leather lacing, etc. to attach the covertec to the key. Just an idea I had.

Wired up the recharge port. Man! Grinding that faucet knob was painful.

Moved the wires on the soundboard from the bottom to the top of the PCB, took off the white connector, soldered in the clash sensor, connected all the (-). Does anyone else have that ??? attached to the bottom of their Anakin?


Having to work outside since I have no garage or a work area that I would want to throw metal shavings around in... really puts the brakes on your productivity.
I finally found a compression sink plug that I could use so I could sand down my sink tube. Messed up the fist angled cut on my sink tube and decided to use it as my brass overlay tube. Cut the second tube angle, painted and glued the pommel & connecting ring, and drilled & attached the 1.5"-to-MHS adapter.


Finally got a chance to work on my saber a little more. Not all sink tubes are created equal. After messing up the 2 that I originally bought from Lowes, I bought 2 more from Home Depot. They didn't fit over the 1.5"-to-MHS adapter. Back to Lowes for more sinktubes and a miter saw. Newly cut sinktubes and the sanded inner grip main body.

Printed out my templates to cut the sinktubes then used a glue stick to attach them securely.

Outter tube rough cut.

Partially cut brass shroud. I thought it would be easier to file these edges before making the final cuts and having to deal with a lot of thin metal. I think I am going to put an angle on the slots to match the 45 degree angle at the emitter. Outter tube sanded and test fit with inner grip tube. Rubberized poly washer grip added to outter tube.


Finished the brass overlay. Hand filed the slots. I need to figure out a softer lighting scheme to take pictures of shiny things.

Brass still needs it's final polishing. Inner grip needs masking and repainting. Outer grip needs a touch up. Still trying to finalize how to get the guts installed and stable.

While waiting for paint to dry on the grips, I have made a switch and accent LED holder from "ShapeLock" low temperature molding plastic. The plastic cylinder was part of the removable blade in the MR Anakin saber that was used to lock the blade into the hilt. The TCSS premium speaker literally snaps into it like it was made for it. I have cut groves in the sides so that the main LED wires can go past the speaker in a reverse speaker configuration.


I built a basic chassis to better organize my electronics. I used 1.5" wooden disks from the craft store which I sanded down, drilled and dremeled outwire and sound holes, and threaded holes for the #8-32 threaded rods. I will add another picture of the finished chassis as soon as I reorganize the guts.

Here are all the guts laid out roughly how they will be installed. The black thing middle/top is the white plastic switch and LED holder that I painted black. The switch and LED have quick connect plugs.

And finally my lightsaber is assembled!!

Here it is, with my dog, in a dimly lit room with flash and without.



I have hidden sound holes in the upper grip area under the two strips running down each side. I need to add more holes in the pommel around the recharge port.
I need to disassemble the guts because the clash sensor needs me to pound the hilt for it to work. It worked great before putting it in the hilt. And there is possibly a loose wire because sometimes it shuts off shortly after I turn it on.
I have a new 1" OD thinwalled trans white blade that I need to get about 5' of wrap into.
When I have all that completed I will post in the Gallery section.

Thanks for everyone's help and comments!!