Dark Rey Lightsaber - Aluminium

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alexbailey

New Member
This is a work in progress, only one side so far, some parts will be in the finished piece, others are just placeholders to check the scale.

All in aluminium so far, that could change as I continue, may use stainless for some specific parts.

The central hinge is a bought part.

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M10x1.5 threaded rod runs through the whole piece, the part that connects to the hinge is tap M10 to lock the thread rod. A nut at the other end keeps the whole together - the nut is temporary until I make the end parts.

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alexbailey

New Member
Done some more work on it, in between actual real work.

One side of the hinge mounted using two M5 bolt - will change to black bolts.

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Other side is thread milled to M30x1.5 to fit in the other side of the hinge and then locked up against a set screw. The set screw is a pretty dodgy solution, but it's fine for this application.

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Also replaced the placeholder part I was using for scale with an actual finished part.

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alexbailey

New Member
Completed another piece, unfortunately rather slow progress.

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This piece is made in 303 Stainless, will enable me to get the blowtorch on it to get the heating effect present on the original.

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It is tapped M10, this part will lock all the other bits together, the outer tube will be locked underneath this part. there's not much clearance between the inner and the outer - its a bit fiddly.

i'm not sure how the original was held together there are quite a few bolt heads. Most of the bolt heads on my are just aesthetic. All the main parts are held together with the M10 threaded bar.

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