So, I got an Ultrasabers Aeon V2 LE stunt saber in one of their "Mystery boxes". I liked the slender design of the hilt but the tailcap end was a bit plain and flashlighty for me. I went to the US forum to see if there was anything I could do to add a pommel to it as the US V@ will not fith any of their larger sized pommels ( which are MHS V1 sized).
I was informed (incorrectly) that the TCSS V2 pommels would fit and that there was also an adaptor that I could use to fit a V1 to my hilt....I was overjoyed!!
I ordered a MSH V1 to V2 adaptor and a basic V1 pommel to start off.....when they arrived I quickly learned that the US V2 and the TCSS V2 have VASTLY different thread Diameter and pitches and it just wasn't going to fit.
I had a few options....I could add more metal to the adaptor and cut new threads, I could tap the new thread pitch into the hilt or I could choose option C....
option C!!! I used my calipers to measure the shank of the threads on the adaptor and realized it would fit nicely into the ID of the hilt so I took my Dremel and a sanding drum and ground the threads totally off the adaptor.
the only problem is that if I epoxy or silver solder the adaptor in I will lose access to the 4-AAA battery pack so once the batteries fail that's it....
so I started looking into replacing the batteries with a smaller pack and that's when I figured "Hell....in for a penny in for a pound"
so I decided to wire it for sound with a better LED setup. I am going with a Nano Biscotte V4 and a Tri-Cree Amber,Amber, White FoC
now the challenge....I need to fit the speaker holder and the metal chassis disc to fit inside the adaptor and be held in place by the pommel being screwed in and the rest of the chassis needs to fit through the 1" opening and into the thin hilt...
so I used Tinkercad to make digital replicas of the chassis parts I plan to use and arranged it and here is the chassis I have come up with so far...
It will fit into the hilt both lengthwise and widthwise but I am still trying to figure out a way to fit a recharge port into the chassis since there is no recharge port part for the MHS V2 chassis and I'd like to be able to charge the battery without having to disassemble the chassis.......any suggestions?
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