ANH Vader Stunt Lightsaber

Poikilotherm

Sr Member
RPF PREMIUM MEMBER
It seems like the dimple is a manufacturing artifact that seems to be on top of a drive insert in the cap
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After much searching and lookups..... I found this thing, it's a car part, used to seal car doors, I bought all the models in the picture, in a few days I will try to install these things on the Barbican, I see similar dimples on it!
 

Poikilotherm

Sr Member
RPF PREMIUM MEMBER
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I didn't expect these little objects to be delivered to me the next day. Several images were taken. I chose one and stuffed it into the hole! Expansion effect, will not fall off.:rolleyes:Tom It would be wonderful if we could be sure that the real Barbican was installed this way !!!!:lol:
 

thd9791

Master Member
RPF PREMIUM MEMBER
Whoa I thought those would fit the countersunk holes up top. That's very interesting that it fits there! On the prop there is a washer beneath the black thing, and its slid off center, as if the washer is too big
 

Poikilotherm

Sr Member
RPF PREMIUM MEMBER
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My Barbican lightsaber was finally finished, I worked out all my problems, and I achieved everything I wanted as planned. I intend to keep the Barbican lightsaber the way it is, and not install switches or wires. Even though all it takes to make it spin is a wire. But because installing a switch may be uglier..... I'm still...

Tom as you said before, I just made this aluminum tail cover. You can also see in the picture that the metal iron back cover is rusty. Now it finally matches the Barbican color, and the weight of the Barbican lightsabers is evenly distributed in the middle. after getting the screw decorative cover, I hesitated for a long time...... Finally I still chose the button switch cap.... Because it's better to draw.;)

I added countersunk screws to the bearing slots to reduce the pressure on the shroud. Countersunk head screws are completely hidden under the shroud, the motor bin has been 100MM in length, and the motor has been extended 85MM in length to accommodate the motor bin and the coupling, and the remaining part is tapped with half of the thread to fix the tail cover. And next to the thread bar opened the through hole can dredge the motor wire. I'm very pleased with the result.
 

thd9791

Master Member
RPF PREMIUM MEMBER
I wanted to say, while these are beautiful machined pieces, we don't know how it's constructed yet or what the black pieces are

since this is a research thread, if people come looking for information, I at least want to clear the record.
 

thd9791

Master Member
RPF PREMIUM MEMBER
What is the width people have found for these black caps? If those are M5 screws this makes sense, but I need to know if they are closer to 9 or 11 in width.
 

Poikilotherm

Sr Member
RPF PREMIUM MEMBER
What is the width people have found for these black caps? If those are M5 screws this makes sense, but I need to know if they are closer to 9 or 11 in width.
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This is a question worth exploring. When I made vader's severed hand and barbican, when I tried to compare with the original image, I was not 100% sure whether the screw on the casting was M5 or M6. Then when I checked the metal Barbican, I found that the metal Barbican countersunk screw seems to be M5, while the casting Barbican countersunk screw is M6. Either THE M5 or M6 matches the black trim cover when I punch holes in the metal Barbican lightsaber. Depending on the depth of the hole and the height of the black decorative lid. Therefore, the width of the black decorative cover is locked at about 11mm.:cry:
 
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thd9791

Master Member
RPF PREMIUM MEMBER
HOLD ON is one of the bolts a knob on the severed hand saber?

your replica is SO GOOD! down to the freaking components and braided metal inside. I'm stunned.

Also, there seems to be space around the whole decorative cap on the Barbican. Yours seem to be closer to being a perfect fit. This is why I was curious, if yours are clocking in around 11, make them a couple mm smaller and thats 9mm. I'm also not following the way the cap matches both m6 and m5 sized heads?
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I guessed M5 because thats the size of the ROTJ Vader Graflex bolts and the pipe stunt bolts I'm pretty sure...and it would make sense to use them across the board for blade core retention. I would love to check out the real size of the bolts on the barbican just in case! The countersunk holes look to be similar in size to the T track width
 

thd9791

Master Member
RPF PREMIUM MEMBER
I'm going to add pictures from my phone, but I'm typing this out now,
I was able to sort of line things up to a point of reference. Also I have a Roman's MPP clamp and multiple kinds of T track to measure as well.
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The mystery part and MPP lever are 7mm high
Mystery part is also around 7mm wid
The MPP sidebar face is about 10mm or 1cm
The T track is 18mm wide, roughly. (I have Gino track as an example and it matches)
little brass screw heads are 4mm

The bored holes on the barbican are 13.5mm top to bottom (the wide part of the oval)
and I'm getting 10-11mm for the caps

I have vintage M5 Oxide bolts that are 11-12mm across the face

I'm 90% sure the ROTJ Vader Gx has M5s (right Sym-Cha ?) and I thought the pipe stunt had the same size, but there's not much to compare it to on that saber.

Checked the severed hand picture and I'm getting 11-12mm for the one visible bolt.
 

Poikilotherm

Sr Member
RPF PREMIUM MEMBER
HOLD ON is one of the bolts a knob on the severed hand saber?
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I didn't know exactly what the knurled surface of the knob looked like, but I could see a slight trace in the picture, so I immediately locked on to
this one, so it was very thick and trimmed on the lathe to the height shown in the picture.:D

This is the screw of M5 that I found recently, and the width is in the range of 11MM.:cry:The black decorative cover completely covers the screws. Tom, as you said before, I need to reduce the width of the black decorative cover. The reduced image is at the end.


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I recently came up with some ideas to shrink the black decorative cap down to 10.70mm, I think it is almost ready now, I will install it when I
finish painting it and see the result.:D


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thd9791

Master Member
RPF PREMIUM MEMBER
so, this is funny, I at some point found a bunch of no logo (or faint logo) bolts that matched the props and the baggies all say M6. Its handwritten so I'll double check (compare them to a tap) but they're not M5. I matched them to the pipe stunt and the Vader ROTJ stunt Gx.
 

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