building a custom saber

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dengar	building a custom saber	Lead	[-]
Posts: 523 (06/24/09 10:30) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	Tags : None I'm thinking about putting together a custom saber. Had a couple questions. How difficult is it to wire the electronics? Is it just a matter of buying the electronic and installing it into the hilt, or is there actual wiring and soldering involved? How big is a standard blade? I am finding a good deal on a hilt that says it has space for 1"x48" blade.
masterbean		#1	[-]
Posts: 806 (06/24/09 10:56) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	well...I'll do my best to answer this. The level of difficulty for the electronics is really up to where you get the electronics. For instance, if you buy all the electronics from say, the custom saber shop, it'll be pretty simple, as in soldering the connections together. But if you plan on buying the electronic components individually at like say an electronic shop or multiple places, then there will be more difficulty as you will have to know what resistor and power source to buy. Also if you purchase all your stuff from tcss, you can get the blade too...otherwise you will have to build that and I'm pretty sure you can get a 1" O.D with the polycarbonate, it's just a matter of finding a supplier that will sell a small enough amount without raking you over the coals... I'm feeling squirrley!!
dengar		#2	[-]
Posts: 523 (06/24/09 12:32) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	okay, I checked out customsabershop.com. I think I might be able to do this. So at customsabershop, they have "complete blade" and they look to be pretty good. My question is, the "complete blade" is just the O.D with the polycarbonate, right? I would still need blade holder, the lights/leds, the screws & hardware, etc., correct? (in addition to any sound/electronics as well I assume)
masterbean		#3	[-]
Posts: 806 (06/24/09 13:31) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	their complete blade means it's the tube, the inner film and a rounded capped end. I don't know if it includes a set screw or not. I'm feeling squirrley!!
dengar		#4	[-]
Posts: 523 (06/25/09 08:32) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	anyone have any experience with nylon blades?
dengar		#5	[-]
Posts: 523 (06/29/09 14:50) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	Well, I purchased a used Master Replicas Darth Vader Episode V Force FX lightsaber hilt....and I guess I'm going to go from there......
dengar		#6	[-]
Posts: 523 (06/30/09 14:04) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	Okay, here we go. I now have two (not one but two!) custom lightsaber projects in the works. The first is a Master Replicas Darth Vader Episode V Force FX hilt I snagged off ebay. No blade and needs a new soundboard. I'll be doing a Custom Saber Shop LED conversion kit with a polycarbonate battle-style removable blade. For the soundboard I think I'll just go the cheap route and pull one from a "toy" saber. I actually have an old Qui-Gon one that will probably work. As you can see there is also a crack in the emitter. I have found a replacement part but I'm not sure how much I care about it. Frackin' sweet. the second lightsaber project is a Lazersabers full-custom hilt. This one is wicked cool, solid, durable, and just all around very cool. However, it's only a hilt and is completely hollow inside, meaning all the rest of the parts need to be sourced and built. Blade, balde holder and LEDs, on/off switch, sound, etc., etc, .... can get very complicated (and expensive!) compared to the used Vader hilt that just needs sound and a blade.
dengar		#7	[-]
Posts: 523 (07/08/09 09:23) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	Well I disassembled the Vader hilt to find absolutely nothing inside....Guess I'm going to have to learn a little bit about wiring and electrical work.... The switch is in working order. The battery pack is oaky. So is the speaker, but I will not be adding sound until down the road a bit. Here's my shopping list. MR or Hasbro FX Vader conversion kit "TCSS style" Battle blade Luxeon III Star Lux-III Lens Holder Luxeon Lens 5 deg BuckPuck 700mA 6-wire ...and some wire obviously. If anyone has any experience with this and can see that I'm missing something or have something wrong please let me know!
masterbean		#8	[-]
Posts: 806 (07/14/09 13:22) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	solder and iron if you don't already have that...otherwise, I believe that's about everything you'll need. Some people do heat sinks for the Luxeon's. I went to Microcenter and picked up some mini heat sinks they had for RAM. I'm feeling squirrley!!
dengar		#9	[-]
Posts: 523 (07/15/09 11:07) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	Yup, got a soldering iron. And a brother-in-law who is an electrician so that may come in handy as well. Just ordered everything this morning (except for the blade). I found out I will need to use a resistor instead of the buckpuck....1.2ohm 3w since my power source is 4.5v (3 AA batteries). The conversion kit does come with a heat sink.
dengar		#10	[-]
Posts: 523 (09/04/09 09:42) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	Done! Here it is without the blade: Here it is with the blade: Here it is with the safety plug:
masterbean		#11	[-]
Posts: 806 (09/04/09 10:13) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	awesome, now you just need the rest of the outfit I'm feeling squirrley!!
bocrebjedi		#12	[-]
Posts: 1525 (09/06/09 00:48) His Worshipfulness MNForce Co-Leader Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	Nice job!
dengar		#13	[-]
Posts: 523 (09/08/09 15:30) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts Report Post	masterbean wrote: awesome, now you just need the rest of the outfit I do have a costume now as well.....though I am pretty certain it is not RL or 501 approvable.

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