Interest Clan Saber Series #6: Darth Maul

I’m curious about how speakers are taken into account in the overall design : roughtly speaking, where are the vents and where do you intend on having the speaker sitting, guabe ?
 
I’m curious about how speakers are taken into account in the overall design : roughtly speaking, where are the vents and where do you intend on having the speaker sitting, guabe ?
They will be emitter facing. The chassis design I have at the moment uses a 25mm speaker however im going to shange it to 28. There are 2 emitter couplers, the static with no vents and the vented one. The vents will still be covered by the oring however I do expect some saound to slip under it. There are multiple areas where sound will escape due to clearances I purposely left wide.

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The benefit of emitter facing speakers is that it will never cancel out the sound of the other hilt when joined. This is a common issue with the rest of the maul designs.

It won't be the loudest but Im sure it will be enough with both of them on.
 
Pre order is live with 10% discount at checkout.

 
Preorder in, I'm very excited to see this in person. It's too bad the electrical interlock idea didn't pan out but that quick connect is so cool and after seeing how your placing the speaker and switch plungers I couldn't resist. The media blast work you had done on the ki adi mundi was perfect and I'm very happy to see it'll be on the maul too.

I should've figured you'd make a ventress to go with this. I'll have to get that one too :)
 
Preorder in, I'm very excited to see this in person. It's too bad the electrical interlock idea didn't pan out but that quick connect is so cool and after seeing how your placing the speaker and switch plungers I couldn't resist. The media blast work you had done on the ki adi mundi was perfect and I'm very happy to see it'll be on the maul too.

I should've figured you'd make a ventress to go with this. I'll have to get that one too :)
Thanks for the support and im sure it wont dissapoint.
 
A few updates.

  • I have received the solenoid and well it's just too small to work properly. So I have decided to get rid of it. On the plus side, It frees up space for the third plunger and make it more stable.
  • I have also increased the size (diameter and length) of the couplers to significantly reduce potential wobble. I was able to move the plungers to a higher diameter and changed them from M5 to an M6 that has a stronger hold (3.5lbs each vs 6.3lbs each). Total hold force goes from around 17.5 lbs to 37.8 lbs
  • I have sent the revised model to the shop and are now waiting on the final quote. Once i get it I will lt you guys know the cost.
I will be offering several versions:
  1. Darth Maul Special edition. This one will have a media blasted body (to resemble the resin casting), zinc plated emitter washers, 2 emitter endcaps, quick disconnect and fixed couplers. The full hilt is made out of 2 different halves. Side A will be made out of 3 sections (Main body, coupling body and emitter), with the coupling section being clockable. Side B will have 2 sections (Body and emitter) and the covertec wheel. You will be able to convert this one in to a mini Maul by using Side A, you will have to flip the coupling section and then use the emitter from Side B to complete. Collectors box designed by Christian Cruz.
  2. Darth Maul DIY edition. Same as above but no media blasting. This way you can do your own style of weathering. Collectors box designed by Christian Cruz.
  3. Mini Maul edition. You will get Side A plus an extra Emitter. Collectors box designed by Christian Cruz.
  4. Side A only (both media blasted or clean versions). No collectors box to reduce cost.
  5. Side B only (both media blasted or clean versions). No collectors box to reduce cost. Lowest cost option.
  6. Individual sections will be available as well for the custom and diy crew
Here is the box layout. The artwork is still in the works but will share it with you once its done.

View attachment 1944464

Thanks.
Once you have the parts, can you do a video showing turning the full staff into the mini-Maul?
 
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Alright a bit more details on the chassis design.

This is the most recent design. Again it uses an amitter facing speaker (28mm) and a separate blade pcb connector pod. The main reason for that is to have enough space for the 28mm speaker if I were to make it a single piece then the speaker would need to be 24 or 25mm.

Im still adding details to it but here it is.
chassis01.png

chassis02.png


A neat feature is that I have the kill sw hidden under one of the knobs, so yo udont have to remove the chassis to activate.
chassis03.png


The chassis will work with the mini maul but you will need an extra blade pcb pod for the second blade. There will be a version in our shop with this configuration as well.

chassis04.png


Thanks.
 
Alright a bit more details on the chassis design.

This is the most recent design. Again it uses an amitter facing speaker (28mm) and a separate blade pcb connector pod. The main reason for that is to have enough space for the 28mm speaker if I were to make it a single piece then the speaker would need to be 24 or 25mm.

Im still adding details to it but here it is.View attachment 1945980
View attachment 1945981

A neat feature is that I have the kill sw hidden under one of the knobs, so yo udont have to remove the chassis to activate.
View attachment 1945982

The chassis will work with the mini maul but you will need an extra blade pcb pod for the second blade. There will be a version in our shop with this configuration as well.

View attachment 1945983

Thanks.
Thanks for all the details guabe , really appreciate :)

An emitter facing speaker is definitely an unorthodox configuration, but I agree with the assessment of not having two speakers facing each others (a common mistake, IMO, with many saberstaffs).
So how does the PCB connects to the chassis ?

The venting from the emitter is a nice way to avoid having your hands convering them. And the hidden kill switch is a neat plus, love it !
 
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