Dark Rey Lightsaber - Aluminium [Many Photos]

[alexbailey]

After turning the profile, I used the same fixture to drill the holes and spilt the ring into 4 parts. I can't spilt all the way through as part would probably fly out of the fixture.

After some work with a file and a belt sander the parts are nicely cleaned up. The bolts are M2 cap heads, however the heads are just rounded off a little on the belt sander and polishing wheel.

All installed on one the central body.

 

[Halliwax]

I’m telling you, this has been a incredible documentary. The craftsmanship is incredible, I really enjoy every update

Glad to see you’re still cracking away with it!

 

[joberg]

Love it to bits...literally

 

[alexbailey]

Made the smaller button mount, highlighted in red.

All the black parts are now ready for anodising, hopefully send them soon when we next have to get anodising done.

And in position on the lightsaber, with a temporary bolt. I may end up glueing this on, depends on how on how I make the button to fit where the bolt is now. I would prefer a mechanical connection, but may not be possible.

 

[Loneken]

Most impressive build ever.

 

[Halliwax]

Glued to this thread

 

[joberg]

No words

 

[alexbailey]

Most impressive build ever.

Many Thanks

 

[alexbailey]

Glued to this thread

Thank you

 

[alexbailey]

No words

Thank you

 

[alexbailey]

I have had the black parts anodised.

The colours are a little harsh at the moment, I think some weathering will help to bring it all together.

 

[joberg]

Pro-Job all the way: super F.A.B. mate

 

[orntar]

Wow, this is an awesome build!

 

[Snow Builder]

Just discovered this incredible thread. Absolutely gorgeous, your craftsmanship is stellar.

 

[alexbailey]

Just discovered this incredible thread. Absolutely gorgeous, your craftsmanship is stellar.

Many Thanks.

 

[alexbailey]

Wow, this is an awesome build!

Thank You

 

[alexbailey]

Pro-Job all the way: super F.A.B. mate

Thank you

 

[alexbailey]

I have started making the final version of the inner end piece. I made the 1st one out of stainless like the outer end piece however for easy of machining I have switched to use a free machining mild steel. particular to cut the little ridge features.

The original on the right and the new blank on the left.

A before and after bore the internal diameter.

Setting up to drill the rough internal diameter before boring it out.

 

[alexbailey]

Still working on this, progress is a little slow at the moment.
I made the form tools today to turn the profiles on the inner end pieces.

 

[alexbailey]

Inner end tube finished

Setup for cutting the slot

The rough turning before rounding off the ridges. Damage on the left is because the part came out lathe chuck luckily the part is still useable.

Here's the turning tool I made for cutting these parts.