ANH Vader Stunt Lightsaber

[Psab keel]

I'd much prefer a machined aluminum part.

 

[PoopaPapaPalps]

Looks a simple enough piece to mill. If you're looking to get into machining, that would be a great place to start.

 

[Halliwax]

If we can come up with all the dimensions I could give it a try and modeling

 

[Psab keel]

Unfortunately I don't have the space, funds or skills to make one myself with a mill. I'd happily purchase several though if someone did a run of them!

 

[Halliwax]

I have no problem casting some If we can all come to a agreement and determine the size of this thing

I could give it a go at modeling and then casting it for us

 

[Halliwax]

bumping this...

 

[thd9791]

Spent around 6 hours going through fuse carriers and breakers and got nowhere.

They turned this ANH Vader motorized saber into a static with black bolts for ESB, and then molded it for Jedi. I wonder if the silver thing on the shroud in the cast was on there for Empire? Seems the brick with the D ring is after they molded it

 

[Jack2155]

Were the T-tracks for the hilt ever discovered? How do you guys re-create it?

 

[Halliwax]

I’m still debating whether that’s t track on the long side of the shroud or the black box..

if we can lock down the dimensions I can print some for us

 

[Poikilotherm]

I don’t seem to have much saved other than pictures etc. I’m not sure what all was discussed now, but there was planning etc for the Barbican.

I can’t give proper credits for photos so if anyone has objections let me know.

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I think the bottom of the Barbican should have no bevel and it should be completely flat. I drew the bottom of multiple structures and 3D printed them all and the result made me think it was completely flat. Then I made the metal iron end on the lathe. The result is good, but the lathe cutter limit, can not dive deep enough groove. It's a shame, but I'm feeling good, though not exactly right.
Barbican Lightsaber I made it on 40MM aluminum tube, the thin wall of the shroud is 6MM thick.

View attachment 1508869As for the Barbican's hexagon socket screw ornament, I found it on the switch, it is metal and the shape is close.

 

[thd9791]

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I think the bottom of the Barbican should have no bevel and it should be completely flat. I drew the bottom of multiple structures and 3D printed them all and the result made me think it was completely flat. Then I made the metal iron end on the lathe. The result is good, but the lathe cutter limit, can not dive deep enough groove. It's a shame, but I'm feeling good, though not exactly right.
Barbican Lightsaber I made it on 40MM aluminum tube, the thin wall of the shroud is 6MM thick.

View attachment 1508869As for the Barbican's hexagon socket screw ornament, I found it on the switch, it is metal and the shape is close.

Beautiful machining job! I really like these ideas - I also agree it should be flat. You nailed the pommel with the bit hole in it, I think that looks super accurate. I'm 90% sure the extra center flange is an insert held into that big hole with a black domed bolt and a loose washer. The extra part is a different colored metal!

Also Kurtyboy correctly identified the black things as screw caps a while back. (unless there's another item that is a better match) There is a kind that has a dimple in the center, and when scratched, they leave the dot in the center. Here are some white ones

 

[Halliwax]

Wicked nice job

 

[thd9791]

That picture from the recent exhibit confirms it, another hole on the left side of the saber
here is is in an older shot. I'm guessing it was a hole for wires, since I can't see a grub screw in there? But the pommel was just open... maybe this is the grub screw for the flanged pommel with big hole

 

[Poikilotherm]

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Thanks for telling me the correct source Tom ！！！ I just found it！！！

For the back cover, I did not use aluminum to make it, because I took into account the unbalanced weight of my Barbican lightsaber, the upper body is heavy and the lower body is light. I am a person with extreme obsessive-compulsive disorder, so IN order to adapt to the equal weight of the whole body, I made them with metal iron, which looks a little black. But maybe after a while I'll consider making an aluminum back cover. And completely solve the whole body weight coordination! I wanted to put motors and other things inside, but I didn't because of other issues. But the current metal iron back cover only in a few days the surface has begun to gradually yellowing. It won't be long before it rusts completely.

 

[thd9791]

I REALLY wonder what that black bolt in the pommel is screwed into...

 

[Poikilotherm]

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I haven't found a suitable one yet. Here are some of the looks I've found so far.

 

[thd9791]

It seems like the dimple is a manufacturing artifact that seems to be on top of a drive insert in the cap

 

[Poikilotherm]

It seems like the dimple is a manufacturing artifact that seems to be on top of a drive insert in the cap

I'll try and keep looking.

 

[thd9791]

I have a new theory - we already have the switch and wire holes (opposing sides whereas on the luke they are on the same side) but what if the double holes here weren't a mistake...

could that third one be the set screw for the pommel? The other two appear to be holes from the grip screws that used to be there

 

[Poikilotherm]

I have a new theory - we already have the switch and wire holes (opposing sides whereas on the luke they are on the same side) but what if the double holes here weren't a mistake...

could that third one be the set screw for the pommel? The other two appear to be holes from the grip screws that used to be there

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I thought about this while working on my Barbican lightsaber internal motor, tail-cap fixing, and other equipment. But I still think they failed when trying to tap the hole. The size of the current hole is 1.6mm, and in another image,the screw feels like it's coming off, but it doesn't rule out that it's dust. So there's a visual error. which makes me think this hole is a failed hole.