Wow, thanks for all the great feedback! It was so much fun to build!
Let's get on with it. So the whole project started with 3D design because I've been dabbling in it a bit and really didn't want to try to scratch build everything. The problem is that I'm very new to it so I'm getting better with hard geometric shapes after doing the Laser Axe project (
https://www.therpf.com/showthread.php?t=283896&highlight=laser+axe), but organic shapes are still really tough for me. So I basically designed the armor, chest plate, belt greeblies and lightsaber and then started the helmet with a rough model from thingiverse that I then distorted and altered in various ways to look more "dopey", like the toy.
So let's start with the lightsaber. For this piece, I wanted the extending tip with a stop inside so I designed it that way. You can see in an exploded view how that works.
And then solid.
Printing on the other hand is always a pain because it's a lot of parts that require a lot of finishing work because I really can't stand 3D print lines on my props. It works awesome for a base, but then I use a combination of sanding, bondo, bondo glaze, filler primer and paint to finish her off. Here are some pics of that process with the lightsaber.
I put metal dowels in this piece to give it strength at the joint because it was too long to print as a single piece.
Rough assembly.
Fiberglass bondo to both smooth and strengthen the connection between the fat handle and the rod that goes in the sleeve.
Bondo glaze.
Painted saber. I used Montana Gold Rasberry for this since the toy isn't really red but more of a hot pink color.
And then the whole thing nearly finished.