Mind you, I'm not saying that the cone fins aren't equidistant in their spacing between each other. I'm saying that the placement of the cone on the saber body shaft is such that neither a fin nor the space between two fins is perfectly lined up with 12:00 (the buttons) or 6:00 (where the Covertec would be, assuming an idealized placement that is 180 degrees from the red button).
Anakin Starkiller’s Darth Maul Assembly Tutorial Thread
- Thread starter Halliwax
- Start date
Mind you, I'm not saying that the cone fins aren't equidistant in their spacing between each other. I'm saying that the placement of the cone on the saber body shaft is such that neither a fin nor the space between two fins is perfectly lined up with 12:00 (the buttons) or 6:00 (where the Covertec would be, assuming an idealized placement that is 180 degrees from the red button).
I went with a Phillips head for mine, since that seems to be accurate to the TMP sabers. However, I switched out the stock socket head screw on my Korbanth Obi-Wan ROTS and replaced it with a more accurate 8/32” socket head just like that one, since the later prequel sabers went that route instead of using Phillips.
So I've built my full saber and am halfway through my BD version. I used a drill to bore out the end a little so I could fit a nut to hold the rod in. This works a treat. Just insert the nut into the hole and then glue it. You need to make sure it's perfectly flat across the top or even recess it a little. I'll be making the end cap this weekend.
Still can't believe these sabers. They are amazing.
Still can't believe these sabers. They are amazing.
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Needs weathering and the Covertec but here's my cut end! I'll post the files and a drawing of the measurements I used in the next couple of days 
Is it just me or is the cut end somewhat evocative of the Crimson Dawn symbol? Fun little coincidence there.
Is it just me or is the cut end somewhat evocative of the Crimson Dawn symbol? Fun little coincidence there.
correct position is against the grooved area, not close to the buttons. Should be just like E Williams just posted. I never seen a version of the saber in the movie with another position than that. If you have one, please post a picture
cheers
Ok, the cut end file and drilling guide (needs a 1.125" Forstner bit) are posted here:
www.thingiverse.com
Here's a drawing of the measurements I used when modeling the cut end detail. You'll need #2 flat Phillips screws, too
Maul lightsaber cut end detail by mooslug
A model of the cut end detail from Darth Maul's lightsaber from TPM.Needs #2 flat Phillips head screws.The second file is for a drilling guide to help hollow out the end of your resin saber hilt. You'll need a 1-1/8 inch Forstner bit. Be very careful when drilling the resin. It's dense and...
www.thingiverse.com
Here's a drawing of the measurements I used when modeling the cut end detail. You'll need #2 flat Phillips screws, too
Needs weathering and the Covertec but here's my cut end! I'll post the files and a drawing of the measurements I used in the next couple of days
Is it just me or is the cut end somewhat evocative of the Crimson Dawn symbol? Fun little coincidence there.
View attachment 1019952
This looks great!! Did you use a paddle bit to bore out the hilt?
Awesome freak’n job!!!
I used a 1 1/8" Forstner bit which is the kind that looks like this:
And this is the specific one I used, $12.45 on amazon (I already had the small Harbor Freight Forstner bit set but it only went up to 1" and the saber needs 1.125)
Freud Precision Shear Serrated Edge Forstner Drill Bit 1-1/8-Inch by 3/8-Inch Shank (PB-008) - The Router Bit Chisel - Amazon.com
Freud Precision Shear Serrated Edge Forstner Drill Bit 1-1/8-Inch by 3/8-Inch Shank (PB-008) - The Router Bit Chisel - Amazon.com
www.amazon.com
The smooth round sides let it run inside of the drilling guide versus a paddle/spade bit which I think would jump out of or around in the thing and maybe do more damage than good. The drill guide makes sure the Forstner bit starts out concentric with the saber end.
Perfect, I always call these things Mortis or Morrison bits.. not even close to the real name lol
I’m finishing up the write up Friday, thanks again for all your help
Weathered and covertec-ed my cut Maul:
And because I couldn't resist I converted it to a Clone Wars version!
The animated show prop's model looks very faithful to the movie prop, overall, with the exception of a black screw in the covertec wheel and a smaller emitter. As a half-hilt, the smaller emitter makes the prop look better balanced overall IMO (maybe the original reason for the change?).
For the modified emitter, I just needed to pick up a few smaller washers. It has two "large" fins/washers versus the TPM version's three. I picked a 5/8 flat washer (Lowe's part 63310) for this which has an outer diameter of just over 1.75" instead of the TPM kit's 2". It's just a bit smaller than the machined emitter plate, matching the show reference. Also printed up a couple adapter rings to help center the new washers on the kit's machined emitter (the inner diameter is larger than the old washers'). The space between the emitter fins looked like it needed to be a little smaller so I replaced the two 1/2" kit washers with some thinner 1/2" flat washers, and used only one 1.5" washer between the larger fins. Because the washer stack is shorter now than the machined emitter plate, I had to drill out the end of the resin hilt to recess the threaded section into the resin.
I modeled up some guesses at what the cut end detail looks like from the few good shots of it that I could find on the show. It appears to be something of a very simplified version of the Master Replicas cut end detail. A stick-on gem from Michael's, silver paint, and a grungy black paint wash and that part is done.
And finished!
Cut end detail pieces and washer adapters are all up on the same Thingiverse entry:
www.thingiverse.com
And because I couldn't resist I converted it to a Clone Wars version!
The animated show prop's model looks very faithful to the movie prop, overall, with the exception of a black screw in the covertec wheel and a smaller emitter. As a half-hilt, the smaller emitter makes the prop look better balanced overall IMO (maybe the original reason for the change?).
For the modified emitter, I just needed to pick up a few smaller washers. It has two "large" fins/washers versus the TPM version's three. I picked a 5/8 flat washer (Lowe's part 63310) for this which has an outer diameter of just over 1.75" instead of the TPM kit's 2". It's just a bit smaller than the machined emitter plate, matching the show reference. Also printed up a couple adapter rings to help center the new washers on the kit's machined emitter (the inner diameter is larger than the old washers'). The space between the emitter fins looked like it needed to be a little smaller so I replaced the two 1/2" kit washers with some thinner 1/2" flat washers, and used only one 1.5" washer between the larger fins. Because the washer stack is shorter now than the machined emitter plate, I had to drill out the end of the resin hilt to recess the threaded section into the resin.
I modeled up some guesses at what the cut end detail looks like from the few good shots of it that I could find on the show. It appears to be something of a very simplified version of the Master Replicas cut end detail. A stick-on gem from Michael's, silver paint, and a grungy black paint wash and that part is done.
And finished!
Cut end detail pieces and washer adapters are all up on the same Thingiverse entry:
Maul lightsaber cut end detail by mooslug
A model of the cut end detail from Darth Maul's lightsaber from TPM.Needs #2 flat Phillips head screws.The second file is for a drilling guide to help hollow out the end of your resin saber hilt. You'll need a 1-1/8 inch Forstner bit. Be very careful when drilling the resin. It's dense and...
www.thingiverse.com
Weathered and covertec-ed my cut Maul:
View attachment 1022904
And because I couldn't resist I converted it to a Clone Wars version!
The animated show prop's model looks very faithful to the movie prop, overall, with the exception of a black screw in the covertec wheel and a smaller emitter. As a half-hilt, the smaller emitter makes the prop look better balanced overall IMO (maybe the original reason for the change?).
For the modified emitter, I just needed to pick up a few smaller washers. It has two "large" fins/washers versus the TPM version's three. I picked a 5/8 flat washer (Lowe's part 63310) for this which has an outer diameter of just over 1.75" instead of the TPM kit's 2". It's just a bit smaller than the machined emitter plate, matching the show reference. Also printed up a couple adapter rings to help center the new washers on the kit's machined emitter (the inner diameter is larger than the old washers'). The space between the emitter fins looked like it needed to be a little smaller so I replaced the two 1/2" kit washers with some thinner 1/2" flat washers, and used only one 1.5" washer between the larger fins. Because the washer stack is shorter now than the machined emitter plate, I had to drill out the end of the resin hilt to recess the threaded section into the resin.
View attachment 1022908
View attachment 1022905
I modeled up some guesses at what the cut end detail looks like from the few good shots of it that I could find on the show. It appears to be something of a very simplified version of the Master Replicas cut end detail. A stick-on gem from Michael's, silver paint, and a grungy black paint wash and that part is done.
View attachment 1022906
And finished!
View attachment 1022907
Cut end detail pieces and washer adapters are all up on the same Thingiverse entry:
Maul lightsaber cut end detail by mooslug
A model of the cut end detail from Darth Maul's lightsaber from TPM.Needs #2 flat Phillips head screws.The second file is for a drilling guide to help hollow out the end of your resin saber hilt. You'll need a 1-1/8 inch Forstner bit. Be very careful when drilling the resin. It's dense and...
Very very cool!!! Thanks for sharing!!
I grabbed mine off eBay. Tight on funds I had to wait a week before purchasing.. when I went to purchase they were all gone. Took roughly another week for a set to be up there
Figured it was because of Starkiller’s latest run lol
This place seems to have them in stock
STAR WARS COSTUMES: : Covertec Lightsaber Belt Clip
Available at JediRobeAmerica.com these Belt Clips are the perfect accessory to carry your lightsaber.
www.jedirobeamerica.com
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