Darth Vader Hero Lightsaber From The Empire Strikes Back?

Gonna need more info on parts! I've got the strobonar and a slave coming from teecrooz and if I can get a final saber as cool as that, I'll be stoked
 
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The grips came from Todd's Costumes they were custom ordered at 4.25". Not perfect, and the grips on the original saber are oddly shaped, but I opted to use traditional track.

The screws I used for the grips and wiper piece are 4-40 button-head allen screws. I got blackened steel so I wouldn't have to paint them.
Side note: you'll need 28 screws for the 7 grips and black steel screws cost about 40 cents each (kinda pricey).

The screws for the d-ring are 8-32 flat-head allen screws. Blackened steel again.

The "clamp" is a 2" strip of rubber I cut from a scrap I bought from a surplus shop. I got the d-ring there too.

The clamp card was made from a blank section of circuit board plastic. I carefully masked and spray-painted the gold lines.
It actually came out better than expected! I recommend "Line O Tape" brand masking tape. They also make pinstripe tape.
1/16" is the perfect size for the space between the gold lines.
I got mine at the local hobby shop.

Everything else was scratch built from either aluminum or styrene.

Good luck!

- - - Updated - - -

Oh - the original appears to have been brush-painted with generic silver and black paint.
For mine, I used Tamiya Gloss Aluminum and Matt Black spray paint.
 
I'm really wanting to build one of these, lately!

Great job on yours, Chris, very clean looking. Did you use a real windshield wiper part, or is that custom made?

I've got my Strobonar, but I'll be in need of a Graflex Slave unit. Anyone have one lying around they can spare?

I'm confident I can make most the rest of the parts in styrene and aluminum stock.

And Chris, thanks for all the tips on the screw sizes, that'll make things easier!
 
redbutton and I both have strobonars now too! He has a slave unit and we realized a 1/4 20 rod can go all the way through. We're planning on sanding down a chunk of dowel to bolt right beneath the slave unit to hold the Heiland in place, as a spacer.
 
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