Okay, I re-read what you described in the first post and it isn't really a problem, that is how the sabers are designed. They are only able to activate with the blade inserted, hence why it only works with the blade secured. To by pass that, you will have to solder the circuit permanently together, as shown in the Anakin removeable blade tutorial here:
http://forums.thecustomsabershop.com...kits-available The only way to get to that soundboard is to break the housing apart at the seams. Clear packaging tape seems to work well for me when putting he housing back together for re-use.
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