I didn't think I'd work on another lightsaber scratch build so soon after my Scratch-built Count Dooku, but as it so happened, when I was looking at ways to display my current PT villain hilts together, my AS lineage Maul dropped and was damaged quite severely in the middle. While I liked the lineage aspect of that project, I was really dismayed by the execution, particularly with the one I recieved. My AS Maul was originally very unevenly matched and off center to each other. I know the real prop was like that but it was particularly bad on mine: it was nearly an 1/8th of an inch off center from either hilts. I had to perform major surgery on the casts I recieved to join them center but it made that joining point particularly weak. It was never meant to be taken apart after I originally modified it.
When it dropped, it cracked the cast in a way where putty and glue just wasn't cutting it for repairs and, in a fit of irrational rage, I smashed one half of cast hilt and threw it away and got to work scratch building my own from PVC and whatever else I had laying around. In total, I think I only worked on this for 5 hours in all. The most time spent on this was waiting for the real part for the round dial to arrive in the post, generously supplied by thd9791.
The measurements I based off of the surviving half of the AS Maul but scaled up a modicum to account for the shrinkage that will happen when I mold and cast this. The red button I machined in aluminium, the screw grub has since been replaced with a custom machined thing reminiscent of the real mystery item, the LED bezel is a leftover from my Palpy hilt builds (also on the to-do list), but all in all, this came together really fast. It's a PVC tube with some thin sheets of styrene wrapped around it for bulk with some putty to hide the seam. That's it. I've got material laying around and more than an idea on how to make the finned emitter/pommel piece, I just need to clear my plate of some projects first.
I want to get all the parts together first before I start molding everything. I want this strictly a Maul build, that's why I moved the ribbed section to where it is on the master, and am planning on casting four of these segments and two of the emitter to wrap around a threaded rod that I have. Molds for the hilt segment will be taken from this same piece for each of the two that comprises one half of the staff-saber. I take a mold of it whole once, and take another only going up to the ribbed section. From those two, I make the four segments I need to make the lightsaber. Cap the cast emitter pieces on either end and secure it with the steel and alu pucks and it'll be job done.
When I get around to it right now, I can't say, but it'll go fast for sure.
Watch this space.
When it dropped, it cracked the cast in a way where putty and glue just wasn't cutting it for repairs and, in a fit of irrational rage, I smashed one half of cast hilt and threw it away and got to work scratch building my own from PVC and whatever else I had laying around. In total, I think I only worked on this for 5 hours in all. The most time spent on this was waiting for the real part for the round dial to arrive in the post, generously supplied by thd9791.
The measurements I based off of the surviving half of the AS Maul but scaled up a modicum to account for the shrinkage that will happen when I mold and cast this. The red button I machined in aluminium, the screw grub has since been replaced with a custom machined thing reminiscent of the real mystery item, the LED bezel is a leftover from my Palpy hilt builds (also on the to-do list), but all in all, this came together really fast. It's a PVC tube with some thin sheets of styrene wrapped around it for bulk with some putty to hide the seam. That's it. I've got material laying around and more than an idea on how to make the finned emitter/pommel piece, I just need to clear my plate of some projects first.
I want to get all the parts together first before I start molding everything. I want this strictly a Maul build, that's why I moved the ribbed section to where it is on the master, and am planning on casting four of these segments and two of the emitter to wrap around a threaded rod that I have. Molds for the hilt segment will be taken from this same piece for each of the two that comprises one half of the staff-saber. I take a mold of it whole once, and take another only going up to the ribbed section. From those two, I make the four segments I need to make the lightsaber. Cap the cast emitter pieces on either end and secure it with the steel and alu pucks and it'll be job done.
When I get around to it right now, I can't say, but it'll go fast for sure.
Watch this space.
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