Here is my take on the Brokeflex.
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I basically did a mash up of the 2 photos above, the screen cap and the Star Wars Show, this was tricky as the 2 props don’t match and the clamp card holder and lever were photoshopped back on the saber in the screen cap.
Sorry I don’t have WIP Shots, But the following was the process I took. I first took a sharpie and drew on the saber where I wanted to cut/what was being cut off. Since the 2 props don’t match, I gave priority to the screen cap for the cuts and bends and priority to the SW Show for the guts. Then with a Dremel, I cut into the clamp and the upper. Many Bothan cutting disks gave their lives to make this saber. Once I made all the cuts, I used the sanding drum bit on the Dremel to round off the corners, figuring melted metal is globby and round. Using various size pliers, I bent the parts to try and match the photos. Next, I used a Butane torch to get the heat stripes and blacken it. The heat stripes came out nicely, but it didn’t blacken no matter how long I held the heat on. Speaking of which, I ended up melting the Graflex guts. I actually like it though, and I don’t usually like mistakes. I am not a “happy little Accident” person, usually. To blacken over the heat stripes, I used Acrylic with a sponge. I sponged on black, then gray, then brown, then a little more black in some areas.
Other than buying the blemished Graflex, I wanted to keep this relatively low budget, as I have been buying and building lightsabers I really can’t afford, lol. I got the D-ring and crystals at Michaels and designed and 3d printed the rest of the parts. I will attach my 3D parts to this reply, in case anyone is crazy enough to want to use them. Starting from the bottom, I put silver tape over the end cap disc on the end cap/ Kobold combo part, installed the Dring, and glued it on the bottom, in the unbroken lightsaber orientation, not the SW Show orientation. I cut the heads off of the rivets and glued them on the grips and Kobold. I hit the clamp side of the grips with a heat gun for about 10 seconds and they melted and curled a little. I then went halfway up the grips with brown Acrylic paint with the sponge. I double sided taped them on the lower in the unbroken lightsaber orientation. I printed the internals that stick out, in brass/gold PLA silk. I did the same black, gray, brown sponging with a little silver for highlights. I stripped some wire and treaded it through the holes in the part, splayed the strands and weathered them with the same sponge method. With the crystals, I epoxied all the parts together and into the Graflex. The clamp card is just printed traces, since the backing is clear anyway. I cut it to match how I cut the clamp and weather it with silver, bronze, and black. I think that is it. It took a while, quite a bit of problem solving, and iterating, but was fun. I hope this helps anyone with making one.
Thanks for looking, Ben