Ok,
So this is a cut and past of post I had running on a forum, but I wanted to put it up here too. I am constructing my own saber to accompany the one I recently got from Randomsabers. It isn’t going to have any fancy electronics, but it will take an acrylic blade.

Here’s a list of all the parts I’m going to be using:

Aluminum tube $8.00 (wholesale)
Black Delrin Rod $14.50 (wholesale)
Graflex Clamp $30.00 (parks sabers)
Graflex Button $12.50 (eBay replica)
Rubber Grips $5.00 (blast-tech)
Mylar Tape $2.00 (blast-tech)
Aluminum Endcap $10.00 (randomsabers)
Covertec Clip/Button $16.00 (randomsabers)
Aluminum Bar $3.50 (retail)
Brass Rod $2.00 (hungates)

So far I’ve recieved my Blast-Tech parts and the Graflex button. The saber probably won’t be done very soon but I’ll keep you posted.

And, yes, it is costing about as much as it would to have it machined by Randomsabers, but I’m kind of impatient, and this is a test to see if I can make a saber myself that is up to par with some of the better made replicas out there.
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I got my aluminum tube today. Its a bit scratched, so it’ll require some sanding to get a respectable finish, but aluminum is easy to sand…

Oh, and the background is one of the sets to my animation…

Here’s the pattern I made for the emitter. It’s a bit of a sharper angle that a real Graflex. I didn’t do the first one, it’s from Ant’s Graflex Project Page.

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Ok, so I couldn’t help working on this even though I have more pressing work to be doing…

Here’s the emitter so far, I taped the pattern around the tube and used a dremel and sandpaper to shape it.

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Here’s a shot of the saber with a mock-up of the grips and inner tube (which will be delrin when I get it, for now I just put a piece of PVC in there).

I am also going to be cutting a 1/2″ off the bottom.

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Ok, here’s 2 progress pics. I just made the clamp ring tonight, it’s not attached yet (well nothing is attached yet really…just taped it all together for the pics)

The clamp ring is the 1/2″ I cut off the bottom of the saber, I cut about 1/4″ section out of it and bent it to fit inside the emitter.

The plate on the back side of the emitter is a section of the tube that I removed to make the S-curve on the emitter.

Cheers.
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I’m waiting for my delrin and graflex clamp to line everything up, then I will drill out the holes for the charging sockets…

After that I will need the covertec button to finish the fin detail on the back of the emitter. I’m also thinking about shortening the grips a bit more, maybe a 1/4″…I’ll have to see it with the graflex clamp to be sure.
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Update:

I got my graflex clamp today and it really makes it look like a saber. I’ll take some pics when I’m not in the middle of a shot on my movie.

I also drilled out the holes for the charge sockets…but haven’t sanded them or anything yet…

Just waiting on my delrin, and parts from Ryan, though I know he has already shipped those.

I had to dremel off the little tabs on the inside of the graflex clamp so I could slide it onto the aluminum tube, I also sanded it so it wouldn’t scratch the tube.
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Here’s everything mocked up so far:

This is a close up of the emitter end:

and here’s a close up of the clamp and charge port holes:

I have already made the four brass pins to go in the charge sockets, and rounded the tips with a dremel and sandpaper.

Wet-sand sandpaper is awesome. With sink drain pipe any nick or mistake you make with a dremel or drill shows up immediately and you can’t do anything about it. With aluminum, all you have to do is sand those blemishes out. It’s great!
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I got my delrin and the endcap and belt clip from Ryan today! I finally have all the parts to my saber!!

Next on the agenda is cutting the delrin down to the right length and attaching it inside the tube. From there I’ll drill out the holes for the charge sockets, and whatnot.

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Update:

I have just cut the hell outta the back of my thumb with a small hand saw!!!

“Do not underestimate the power of non-electric hand tools
-or suffer my fate you will…”

Also, I have cut out the final and most difficult parts on the aluminum bar. As well as cut out and drilled holes for the charge socket pins.

“Everything is coming together just as I have forseen…”

P.S. -it’s not so bad I need stitches if any of you are worried…maybe a little close to needing them for comfort but I’ll be ok.

I think I’m going to add another strip of aluminum before I attach the covertec button, to raise it up a little more…

Notice the band-aid…the pins aren’t glued yet so there’s tape over the holes.

Here’s my saber at home w/ my new blade!

For all of you out there who probably care less about this than figuring out what exactly that IS in the back of your fridge:

It is almost upon us! This is my saber in it’s current state. There are still a few things to be tweaked, but its basically done. Run for your lives dark lords!!!

Randomsabers

So, you may or may not be aware that I am a total loser. Regardless, my custom lightsaber should be done very soon! I can hardly wait. I mean a man needs to defend himself right? This is serious. Oh, and I designed it, and it’s one of a kind, and don’t try to copy me you uncreative leech Star Wars fanboys!!! You know who you are.

It’s named “Claiómh Solais” (ClĀv SŌl-ish) Which is Irish Gaelic for “sword of light” It comes from Irish mythology and is the name of the sword carried by Nuada (Nuadu) Airgetlám (of the Silver Hand). It is also attributed to Cúchulainn (many variants). It can also be alternately spelled “Claidheamh Soluis”. Either way, I am definetly a nerd.

It’s design is derived from the saber carried by the Sith Lord Darth Radimus, which lost it’s power cells when it was destroyed in a fit of rage by Radimus himself. It was later repaired by his apprentice, who kept it for himself before deciding to abandon the Dark Side for the Good. It also takes some design cues from the Original Trilogy Obi Wan saber.

My next saber (if there ever is one)…Ok, so thereprobably WILL be…will be named “Caladbolg”, which means roughtly “Lightning Sword” attributed to many mythological Irish heros. A variant of the spelling “Caledwlch” is the name used in early Welsh Arthurian legends for the sword of Arthur (Excalibur).