Building my 1st saber, NOW with Advacnded Action!!

[Bigdaddy]

I'm attempting to make my 1st hardware saber, sort of. I'm a very practical person (sometimes :rolleyes), so I thought for my 1st attempt at a prop, making something I can use everyday would be a good place to start in the hobby.
Something I need for work: A powerful, durable, adjustable beam magnetic flashlight.
Seems like a Saber is the way to go with this. I've looked into a lot of flashlights and the old Mag-lite is really the best choice, plus I already have 2 I've done a seach and have seen a few Maglite conversions, but not one that allows it to still function as a Mag, so what I'm really doing is dressing up a maglite as a saber without losing its functions:lol
So far I spent $40 on stuff at the hardware store that won't work for anything (Dammit Jim, I'm a carpenter not a plumber:facepalm), the light shaft is 1 1/2" D. I'm thinking about getting a clamp/box from Customsaber, but it's 1.45 D, so I would have to cut it, any thoughts on this?

 

[PurpleDiamond]

Re: Building my 1st saber (sort of)

I have not made a lightsaber yet, I am planning on making one for my daughter and it will definitely have some functionality so I have started thinking about the problem. The solution I see to the problem is using a smaller flashlight and encasing it inside a lightsaber grip. I am thinking of using a painted PVC to keep the weight down.
The inexpensive LED flashlights sold at Home Depot or Lowes in a 2-pack are about the size that I am thinking of using.

 

[ncc74656m]

Re: Building my 1st saber (sort of)

I have not made a lightsaber yet, I am planning on making one for my daughter and it will definitely have some functionality so I have started thinking about the problem. The solution I see to the problem is using a smaller flashlight and encasing it inside a lightsaber grip. I am thinking of using a painted PVC to keep the weight down.
The inexpensive LED flashlights sold at Home Depot or Lowes in a 2-pack are about the size that I am thinking of using.

Might I recommend looking at some of the prebuilt units from places like Ultrasabers? Not necessarily to buy, but for inspiration, and also at the related forums?

There are much better alternatives to flashlights, and of course, the incredible polycarb blades premade through them and The Custom Saber Shop. I always recommend a high output LED like Luxeons and Crees over some cheapy flashlight that, unfortunately, will disappoint.

If you don't care about having sound, you can get the LED of your choice, the driver board for it, and the lens/mounting stuff for probably $15 or less total.

If you'd like more detail and some suggestions, let me know, or better, PM me, since I don't know what's allowed in terms of direct linking and such.

 

[Bigdaddy]

Re: Building my 1st saber (sort of) HELP???

I have not made a lightsaber yet, I am planning on making one for my daughter and it will definitely have some functionality so I have started thinking about the problem. The solution I see to the problem is using a smaller flashlight and encasing it inside a lightsaber grip. I am thinking of using a painted PVC to keep the weight down.
The inexpensive LED flashlights sold at Home Depot or Lowes in a 2-pack are about the size that I am thinking of using.

Thanks for posting, so far all the small flashlights I have looked at don't have an adjustable beam, and seem rather flimsy (being mostly plastic) I need a metal flashlight that functions not as a saber but as a maglite and can withstand rough use in sub-zero temps for 30 min or more, plastic tends to become brittle (I've broken a few lights because of the extreme temp)
Has anybody sliced a box/clamp from Customsaber lengthwise to make it fit a larger shaft than 1.45? I have almost no experience with metal work here :$, also looking for a "part" to fit over or wrap around the lamp hood. My goal here is when I'm wearing my Mag for work people will see it and think "Lightsaber", intead of "flashlight":cool

 

[SofaKing01]

Re: Building my 1st saber (sort of) HELP???

The only sugesstion I have is to jump in and do it... Not really sure if that helps?

 

[Bigdaddy]

Re: Building my 1st saber (sort of) HELP???

Any suggestions on a metal to metal epoxy? I'm thinking I can slice the collar on my table saw, mount the covertec button to that, then slip the collar onto the shaft and keep it in place with an epoxy or glue. I was considering the blade holder from customsaber as well but I think it will restrict the light beam.
SK: I can't argue with you on that appoach after seeing where it got you! :thumbsup
I'm ordering the box/collar, covertec button, and the blade holder today...if any parts don't work for a flashlight I'll turn one Mag into a "saber". Nice to have 2 Mags, allows for mista...er "learning experiences" :lol

 

[PurpleDiamond]

Re: Building my 1st saber (sort of) HELP???

I have had great experience using JB Weld epoxy cement. I highly recommend scuffing up the surfaces that will be glued together to make a better bond.

 

[Bigdaddy]

Re: Building my 1st saber (sort of) HELP???

I have had great experience using JB Weld epoxy cement. I highly recommend scuffing up the surfaces that will be glued together to make a better bond.

Great thanks :thumbsup

 

[SeanMcShaft]

Re: Building my 1st saber (sort of) HELP???

Here's where I got the plans for my first saber build. No electronics just good looking cosplay shells. Really well documented site, shopping lists, and several good designs.

Lightsabers from the Big Yellow Box

Cheers

 

[Bigdaddy]

Re: Building my 1st saber (sort of) HELP???

Thanks sean cool site :thumbsup

 

[Organic Mechanic]

Re: Building my 1st saber (sort of) HELP???

As for making the box fit a larger diameter than it was made for:

If it's aluminum (other metals are too hard), and you've got the patience, cover your flashlight in painters tape, wrap some heavy grit sandpaper (80 grit shop cloth is a good choice) around it, and start sanding the desired portion by stroking it lengthways along the tube.

It will take all darn day, but it will make for a perfect fit. Not to mention that your epoxy will love the finish of the 80 grit.

 

[The Schlitzie]

Re: Building my 1st saber (sort of) HELP???

I haven't tried it myself,but I think Ultrasabers or TCSS has conversion kits specifically for mag lights. A maglite with some t tracks on it might look cool.

 

[pfillery]

Re: Building my 1st saber (sort of) HELP???

Most of the types of tubes, be they steel or aluminium, should have another size that fits snigly inside them as well as outside them. So if you hunt around long enough you should find something.

But if your OD is 1 1/2" isn't this the size of a graflex clamp and a lot of the add on clamps around? The beauty of a graflex clamp is the size can be increased or decreased within reason. Otherwise it is scratchbuilding all the way (more fun that way).

Search for some other builds on here for inspiration.

 

[Whovian]

Re: Building my 1st saber (sort of) HELP???

rather than a Mag-lite or other metal flashlight, you might want to research sink tube sabers online first. A typical sink tube is about the right diameter, and comes in various lengths. With additional hardware parts or even a kit from someplace like Blastec, you could have a really good first saber.

 

[thd9791]

Re: Building my 1st saber (sort of) HELP???

Exactly, I actually just made a sink tube saber, and most of mine have been. Big Yellow Box has some great designs on there. I personally use that site for basic instructions on how to make skeletons for lightsabers, cores, how to attach parts together, which tubes and washers fit with what. It's a treasure trove of information. There is the option of fitting a flash light inside something like a sink tube saber, and getting the switch accessable....I have yet to do that haha

 

[Bigdaddy]

Re: Building my 1st saber (sort of) HELP???

As for making the box fit a larger diameter than it was made for:

If it's aluminum (other metals are too hard), and you've got the patience, cover your flashlight in painters tape, wrap some heavy grit sandpaper (80 grit shop cloth is a good choice) around it, and start sanding the desired portion by stroking it lengthways along the tube.

It will take all darn day, but it will make for a perfect fit. Not to mention that your epoxy will love the finish of the 80 grit.

Thanks for the tip OM I'll give that a try :thumbsup

On another note, I ordered some parts from CSS pictured below. When I went to change the batteries in my big mag I found they had corroded solidly into the shaft:angry! So I'm getting a new 4 Dcell that will have LED (mine was an old school). I salvaged all the parts from the old light and am going to attempt to cut down the reflector (plastic) to fit inside the bladeholder. Still working on pommel concept, There are some nice ones at TCSS but non are compatible with the Mag shaft, I might end up getting one and having it modified to epoxy over the end cap on the light.
This is becoming a rather expensive flashlight! When I brought the idea up to my wife I assured her I wouldn't "go crazy" with this, just pick up a few things at the hardware store :behave:lol I think I'm developing a habit!

 

[Sym-Cha]

Re: Building my 1st saber (sort of) HELP???

Hi there,

Be aware ... I can sense the screen-accuracy-bug lurking in this thread


-Chaim

 

[Bigdaddy]

Re: Building my 1st saber (sort of) HELP???

Hi there,

Be aware ... I can sense the screen-accuracy-bug lurking in this thread


-Chaim

It's everywhere! :lol I've been seaching through saber threads and after this project I can certainly see attempting a screen accurate saber for display! My wife is very cool with unorthodox decor love

I went to the hardware store and picked up another Mag-lite, I went with the 3 D cell, the 4 looked like it would be cumbersome for work, and I want the magnet to be able to hold it steady and properly directed at any angle.

 

[Bigdaddy]

Re: Building my 1st saber (sort of) HELP???

The past weekend was very good! On friday I received the non- SE OT Trilogy, Saturday when I got home frome work my saber parts were here as well:thumbsup. I intended to get going sunday but life conspired against me, so I started this morning while watching Star Wars in all it's Original widescreen glory:cool. There is something very magical about sitting among a bunch of lightsaber pieces and tools while that score and the sound of the Imperial ship thunder out of my speakers!!cheers

The blades I have for my tablesaw are all for wood cutting, so I had to work with the few tools available, utility knife and small file. I started by scoring the box a few hundred times and then going to the file, and finally finishing with the knife again. I ordered an unpolished box because I knew I'd be manhandling it quite a bit. The resulting cut is quite ugly but straight and I'll buff and polish the box after assembly

 

[Roshanini]

Re: Building my 1st saber (sort of) HELP???

I'm attempting to make my 1st hardware saber, sort of. I'm a very practical person (sometimes :rolleyes), so I thought for my 1st attempt at a prop, making something I can use everyday would be a good place to start in the hobby.
Something I need for work: A powerful, durable, adjustable beam magnetic flashlight.
Seems like a Saber is the way to go with this. I've looked into a lot of flashlights and the old Mag-lite is really the best choice, plus I already have 2 I've done a seach and have seen a few Maglite conversions, but not one that allows it to still function as a Mag, so what I'm really doing is dressing up a maglite as a saber without losing its functions:lol
So far I spent $40 on stuff at the hardware store that won't work for anything (Dammit Jim, I'm a carpenter not a plumber:facepalm), the light shaft is 1 1/2" D. I'm thinking about getting a clamp/box from Customsaber, but it's 1.45 D, so I would have to cut it, any thoughts on this?

Good luck