So I let this thread go dormant for a while, but I've been hard at work on this saber design. I was very fortunate to get my hands on some high resolution pictures of the hero prop. Unfortunately, because they are not publicly available I cannot post model overlays or comparisons to them. All that being said I want to show my progress and discuss several aspects of the design.
First the model:
Now some updated comparisons to readily available reference images:
A couple features I want to highlight:
1) Emitter Shroud:
This piece has been the biggest challenge, I have easily modeled and remodeled this part 30+ times, but I really feel like I finally have it nailed down. This is not a simple axially symmetric part with 3 sets of evenly spaced features. Each cutout and feature is a different shape and size with unique spacing. The corner radii on the right side of each emitter "post" are larger than the radii on the left side. The groove is not a simple rectangular cross section made with a grooving tool on a lathe, but remnants of a regular profiling tool that was lightly touched off against the surface:
I spent a lot of time visualizing how this part was originally manufactured to figure out a solution that both makes sense and perfectly overlays against reference images.
2) Pommel Cubes:
I believe the pommel cubes are not one solid ring-like part, but 6 individual pieces. A couple features I haven't seen on any prior replicas:
- There isn't a uniform gap between the bottom surface of the cubes and the pommel. The bottom surface of the pommel cubes has an oversized radius that touches the pommel at the center, but not at the edges.
- The edge closest to the pommel facing away from the emitter has a somewhat prominent chamfer on it
- The portion of the cubes that is inside the pommel grove does not have a curvature to it, but a flat bottom leaving a small gap on each side
As the model is getting closer and closer to completion, I've been thinking more and more about construction methods, which I think is a good area for discussion.
Discussion: Construction Method
In my mind there are two prevailing options for how the prop was originally assembled:
- The saber was more hollow with a threaded rod going from pommel to emitter
- The saber was built around a solid core
In a very general sense I've modeled how I see these two options working. Below are cross sections of the options with approximate masses calculated by Solidworks using appropriate materials for each part (aluminum, delrin, steel).
Option 1: Hollow w/ long threaded rod (Mass: ~550 grams)
Option 2: Solid Core (Mass: ~606 grams)
On the one hand Option 1 seems more practical to me, the prop makers probably had some hollow aluminum tubing and threaded rods just sitting around the shop, on the other hand Option 2 would be more solid and still would not be very difficult for them to make. I am really interested to see what other people think.
I have some other exciting potential developments in the works so stay tuned...