custom billet shroud CPI

**infa008** · 12-10-2009, 01:49 PM

Hello sabersmiths,
Here is some pics of a shroud that I machined for my existing saber. Ever since I heard of Erv's Buttered Toast, I was just unhappy with my direct drive Lux V green. So I've been doing some CPI(Continuous Process Improvement). Anyway, I still have some work to do with it all ie polishing. It was a very difficult set up in the mill but came out ok. I sort of crushed it alittle so i have to bend it back to make it fit the saber. It doesn't go all the way on yet. And I picked out the wrong chunk of alluminum (T4 instead of T6), so it was impossible to get a smooth bore even with my 1" solid carbide bar, but luckily the milling of the profiles gave me a decent finish. It took an hour and a half to run the mill program on the OD profile with a 4" long endmill. but thats a decent time. still plan to anodize and powdercoat things in the future but my next project is to make a sliding door on the OD of the bottom half of the hilt so that when i Finally get my hands on a CF board, I will be able to slide it back to access the SD card and battery pack if need be. Wish me luck.

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Finally got it to fit all the way.

**Clockwork** · 12-10-2009, 02:10 PM

Very nice!

**ARKM** · 12-10-2009, 02:39 PM

Cool.

**Kal El Rah** · 12-10-2009, 03:04 PM

Looking good so far.

**MakillaGorilla** · 12-10-2009, 04:29 PM

There's a half-naked child in one of those pictures.....Aside from that though cool idea. How'd you get such a clean cut on that?

**jedimastergarcia87** · 12-10-2009, 07:32 PM

Oh my god, its the kid from The Grudge! XD Cool saber though. I have that same blade holder with my US MHS hilt.

**infa008** · 12-11-2009, 12:12 AM

Originally Posted by MakillaGorilla

There's a half-naked child in one of those pictures.....Aside from that though cool idea. How'd you get such a clean cut on that?

sorry my daughter snuk in there.

as for the clean cut. all of the OD profile is one continuous cut programed into a CNC and programmed through mastercam. I had it chucked up vertically and made the the profile cut all the way around at .100" per cut until 3.500" deep and then stepped the cutter compensation in .005" and made one final pass at the full 3.5" depth. then I ball nosed a groove in the top and drilled 4 holes to let some light peep through. Oh and I used a brand new 1.5" X 4" 6 flute endmill.

The blade holder and all I machined myself out of solid round stock. the blade holder is solid brass, I got the idea for it from one that I saw but I added the ball nose flutes for a unique flair.