Alluminum Rod + Dremel = Lightsaber ?

[AJLoCascio]

Was toying with the idea of making what is probably my 7th lightsaber - Just got a dremel and was thinking about getting a solid aluminum rod and cutting into the sucker.

1st off : is this possible?

2nd : If so - any tips for doing this with a dremel and what kind of saw to use ?

Here's the design I have in mind:

Cheers
-AJ

 

[WhiteShadow]

i believe that within a few minutes, you would find that while doing something like this is certainly possible...if you had enough time and patience...a dremel is probably not the best tool to use for what you're trying to achieve. i would assume you'd need an incredible stock of heavy duty cutoff wheels and probably a couple of backup dremels as well. personally i've made my sabers using a high speed hammer drill that i rigged into a simple metal lathe...i'd think a lathe would be the only way to ensure an even depth on the cuts you'd need to make...do it in separate pieces...solid core, and then use the dremel to cut aluminum tubing for your shroud and what not...ciao

 

[JLeezy23]

I wanna make my own too, my design has the grip kinda like yours and i might use metal o-rings to fit exactly over a sink pipe. I need to google more stuff while i'm in Home Depot to see which parts i need, i did thar before with other projects and the workers point you in the right direction

 

[kursosawa]

go over to thecustomsabershop.com and check out their MHS section. You could construct something very similar to what you had in mind with the parts from that store. Though I would agree with white shadow on the bit about the grip section: a lathe would be the best way of getting even cuts. Though you could cut the emitter shroud and grip overlay using a dremel and sink tube with some practice and patience.

 

[seelsa73]

I don't know anything about actually making a lightsaber myself, but that is an awesome design! It looks like a combination of almost every major good guy's lightsaber from the movies...Obi-Wan Ep1, Qui-gon, Luke ROTJ with the pommel and choke and ANH/ESB emitter shroud. Very cool. I'm looking forward to seeing the final product.

Maybe u can find someone to go in with and have him/her lathe it for you and market to other lightsaber enthusiasts...i would buy one of them lol. Just a thought.

 

[wuher da brewer]

One thing I'd definitely recommend is a template if you want to make more precise cuts. You'll also likely need a flex shaft if you want to cut those grooves because the thickness of the dremel is going to prevent you from cutting more than a certain distance from the edge. Flex shafts are harder on the dremel. It's much, much easier to burn out the brushes on a dremel while using a flex shaft.

 

[franz bolo]

That looks like a job for a lathe not a dremel.

FB

 

[AJLoCascio]

So I guess I wont be going the dremel route.

And after looking at custom sabers and looking at my dawing - it doesn't seem they have the right parts.

Where could one go to get something machined with that body design from a solid piece of aluminum or steel ? Of course I would just make the shroud. and any over lay details.

 

[AJLoCascio]

I don't know anything about actually making a lightsaber myself, but that is an awesome design! It looks like a combination of almost every major good guy's lightsaber from the movies...Obi-Wan Ep1, Qui-gon, Luke ROTJ with the pommel and choke and ANH/ESB emitter shroud. Very cool. I'm looking forward to seeing the final product.

Maybe u can find someone to go in with and have him/her lathe it for you and market to other lightsaber enthusiasts...i would buy one of them lol. Just a thought.

Thank you !

I guess it was a very subconcious theft of design, as I drew this years ago in college to alleviate boredome.

 

[AJLoCascio]

Here it is with measurements

 

[Anakin Starkiller]

Why not try using different size washers to make the grip?

 

[TMFX]

If you want to build this yourself and don't want to get a lathe but would like to use aluminum, you can't make it from one piece. Not only because it is metal, but also because aluminum is non-ferrous and will cause cutting wheels to explode from heat buildup as they clog with melted aluminum.

You can buy discs of aluminum from mcmaster.com and stack them, or cut and sand the ends of lengths of different diameter aluminum stock, also available by the foot from mcmaster.com. You may also find a metal supermarket or something like that more local to you.

Once you have the discs laid up, you can spec out aluminum tube by the inside diameter and wall thickness (best to do while planning) to slide over and become the control section, and just cut that angle-sided pocket out with a hacksaw. Same for the projection end, cut that contour out with a hacksaw and then use a dremel with a drum sander to put the round in the corners. I'd also suggest adding a round in the the corners to the control section pocket cutout, to help fabrication.

You can use LORD brand glue to glue aluminum, or 5 minute epoxy available at any hardware store, you just want to give it some tooth by sanding the surfaces.

It's definitely doable, if you'd like to have it made, our shop can definitely handle the whole thing, or machining parts to your drawing so that you can build most of it.

 

[AJLoCascio]

If you want to build this yourself and don't want to get a lathe but would like to use aluminum, you can't make it from one piece. Not only because it is metal, but also because aluminum is non-ferrous and will cause cutting wheels to explode from heat buildup as they clog with melted aluminum.

You can buy discs of aluminum from mcmaster.com and stack them, or cut and sand the ends of lengths of different diameter aluminum stock, also available by the foot from mcmaster.com. You may also find a metal supermarket or something like that more local to you.

Once you have the discs laid up, you can spec out aluminum tube by the inside diameter and wall thickness (best to do while planning) to slide over and become the control section, and just cut that angle-sided pocket out with a hacksaw. Same for the projection end, cut that contour out with a hacksaw and then use a dremel with a drum sander to put the round in the corners. I'd also suggest adding a round in the the corners to the control section pocket cutout, to help fabrication.

You can use LORD brand glue to glue aluminum, or 5 minute epoxy available at any hardware store, you just want to give it some tooth by sanding the surfaces.

It's definitely doable, if you'd like to have it made, our shop can definitely handle the whole thing, or machining parts to your drawing so that you can build most of it.

Wow - thanks mate !

I'm toying with the idea of having parts machines. I'm in talks with someone now regarding machining the main body. What would be your the price for something like that ?

Cheers!

-AJ

 

[ChuckNorrisAmen]

I like your design. If i were working on such a design...I'd say a lot of your idea can be achieved with groups of fender washers. I'm working on a hardware Luke ROTJ lightsaber and my design is based primarily on lots of washers. I'll tell you some of the cheapest you can get - Home | Fastenal. I'm eager to see what this project turns into. Good luck!

 

[Lichtbringer]

I really like your design, something that happens not very often with custom designs. :cool

In fact i like it so much i might give it a try, some day - maybe pommel and shrouds from Alu, neck and emitter from brass, and the grip-parts in black (Delrin/plastic).

 

[JLeezy23]

go over to thecustomsabershop.com and check out their MHS section. You could construct something very similar to what you had in mind with the parts from that store.

That seems to work great, but its totally dreadful on my phone! I gotta get to a computer n check that out. I got the main body n the blade holder part of mine done then touch screen crap starts messin me up when dragging parts, but i will check it on a regular computer :thumbsup

 

[WhiteShadow]

Need a custom machined lightsaber for your costume? - You have come to the right place.
the link above is for RandomSabers...they have a couple of hundred different designs available for sale ranging from stunt sabers (no electronics and basically just a solid hilt designed to hold a polycarb "blade") to fully equipped electronic sabers...

best part is that if you send them your design, they can quote a price for getting it fabricated...i think if they like the design, you get a discount if you let them use it for future customers...FYI

this one kinda looks like your design

 

[Kris Lyssara]

Need a custom machined lightsaber for your costume? - You have come to the right place.
the link above is for RandomSabers...they have a couple of hundred different designs available for sale ranging from stunt sabers (no electronics and basically just a solid hilt designed to hold a polycarb "blade") to fully equipped electronic sabers...

best part is that if you send them your design, they can quote a price for getting it fabricated...i think if they like the design, you get a discount if you let them use it for future customers...FYI

this one kinda looks like your design

Actually, Ryan isn't taking any new orders for a long while. And they don't have "A couple of hundred different designs available for sale".... every saber in the gallery there is unique and one-of-a-kind, and will most likely never be replicated, at least not by Ryan. There's no discounts if you let them use it for future customers, and it's not cheap to begin with. I'm actually working with Ryan right now on a design that I've been perfecting over the course of the past four years while he works through the current backlog. I know what I'm talking about here.