This really is a great thread and I'd hate to see it disappear so soon, so I thought I'd go ahead and post my early experiments in saber-craft to justify a bump. Like I said before, these were made as stunt props for my fanfilm, so I intentionally left them fairly plain. Some day I might revisit them and add some greeblies and details, but odds are pretty good that I'll just write these off as "learning experiences" and make future sabers more interesting.
WARNING: ugly n00b-sabers ahoy..
Sorry for the crummy pics, but when I took these all that I had was my cheapy camera-phone. :/
A single-handed saber, measuring in at about 8":
Standard sink-tube body with the flared end as the emitter and a shower head pommel. I cut out the details with my dremel and inserted a piece of that ribbed tubing that they use to cover wads of computer cables. The knob is from a cheap cell phone case, but I've since removed that and replaced it with a little D-ring made for hanging pictures.
A double-saber measuring about 22":
Also has a sink-tube base, but since the polished brass tubes are so expensive and hard to find in this length I sanded all of the chrome from a silver one (the hand cramping was intense, but worth it in the end). The grip sections were cut from PVC and coated in plasti-dip (although I now wish that I'd used regular paint, because it's peeling a bit at the edges). The D-ring is for hanging pictures and I added that little brass disk so that the silver D-ring wouldn't be so obvious.
I painted all of the pop rivets black before I put them on, which sort of worked, but not very well. Between the paint peeling from rivets, the plasti-dip peeling from the grip and the chrome tarnishing the whole saber has a splendid, weathered look to it that really works with the character that it was designed for, so even though it's really not much like what I'd originally wanted, I've gotten quite fond of it (which is good, because I'll be the one fighting with it in the film

).
The design is asymmetrical because I wanted to experiment with a kind of "long form" style that uses an extra long saber with a 4+ foot long blade in a thrusting, spear-like style (sort of like what's happening in my avatar - that's a 6' quarterstaff I'm holding there). The second blade is a hold-out for evening the odds against multiple opponents.
Both sabers are assembled primarily with pop-rivets and have a center tube that holds a female threaded pipe fitting in place. I fitted some male threaded fittings to 3/4" oak dowels, so they can be screwed in for fighting.
I've made two others, but I don't have any pics yet. Maybe I'll get a chance to snap a few this weekend and share them on Monday.
EDITED to add a pic of the D-ring and fix some crappy spelling.