Dewy and Anakin Starkiller's Accurate Qui-Gon Jinn Lightsaber Design

[thd9791]

Didn’t think of it until now - I would guess the pommel. Great thought… I feel a little silly not realizing you cant slide the sleeve on

I can’t see any seam line on the bottom of the cone section near the emitter, there are photos at the beginning of the thread on the belt of a mannequin that would most likely show a non-concave corner of those were two lathed parts faced/flat

So…yeah… the pommel might be a separate piece

 

[Dewy]

UPDATE:

1. Finish scaling exercise and determine overall length COMPLETE 4/8/23
2. Scale “flexible” Solidworks model to final dimensions COMPLETE 4/12/23
3. Complete assembly engineering COMPLETE 4/14/23
4. Use dimensions from #2 to re-model in production grade fashion with assembly features from #3 COMPLETE 4/14/23
5. Put finishing touches on model (fillets/rounds/chamfers), ensure tolerances allow for clearance for assembly, obsess over the most minor of details, etc.
6. Don’t look at model for 72hrs, then with fresh eyes and mind give the model one final thorough review (this step is key)
7. Send model to Anakin Starkiller for him to do what he does (prototyping and production!)

I finished re-modeling the saber at the correct dimensions with the updated assembly features. Still want to think about this assembly method some more, but wanted to share with the group in the meantime.

 

[lesternessman]

Looks good to me! You’d never know they were there.

 

[AnubisGuard]

Looks sensible to me. Broadly speaking, it's reminiscent of the old Larbels – end cap screws on a threaded post, emitter threads on, screw through the Covertec and sleeve, and a fake machined washer under the red button.

 

[Eruonen]

All I know is that I can’t wait to hang one of these on my belt. #TakeMyMoney

 

[BRRogers]

Here’s a resin stunt with metal emitter parts:

View attachment 1688884

Huh.
Looks like a T nut welded inside the ID of a washer

 

[Dewy]

UPDATE:

1. Finish scaling exercise and determine overall length COMPLETE 4/8/23
2. Scale “flexible” Solidworks model to final dimensions COMPLETE 4/12/23
3. Complete assembly engineering COMPLETE 4/14/23
4. Use dimensions from #2 to re-model in production grade fashion with assembly features from #3 COMPLETE 4/14/23 & COMPLETED AGAIN 4/16/23
5. Put finishing touches on model (fillets/rounds/chamfers), ensure tolerances allow for clearance for assembly, obsess over the most minor of details, etc.
6. Don’t look at model for 72hrs, then with fresh eyes and mind give the model one final thorough review (this step is key)
7. Send model to Anakin Starkiller for him to do what he does (prototyping and production!)

I didn't like the press-fit / glued down option, but I do feel like the part that the red button screws into should be a separate piece so we can get extra thread engagement. So here's what I have come up with:

Design best practice is to avoid flat bottom holes for manufacturing reasons, but this will be relatively shallow (9mm deep x 14.5mm diameter), in a soft material (delrin), and will likely done by interpolation on a CNC mill so it shouldn't be an issue.

 

[Dewy]

Shoutout to Halliwax so he doesn’t miss the thread.

 

[Joby Wan]

Reserved for additional model pictures! Be sure to check back!

Hello. This looks amazing! Thank You for all of your hard work on these sabers. I missed out on the Obi Ep 1 Saber. I want to sign up for the Qui Gon. I’m new to the RPF so just wondering how and when will I do that. Thank You again!

 

[Dewy]

Hello. This looks amazing! Thank You for all of your hard work on these sabers. I missed out on the Obi Ep 1 Saber. I want to sign up for the Qui Gon. I’m new to the RPF so just wondering how and when will I do that. Thank You again!

Follow this thread, when the time comes we will post a link to the sign-up thread in the Project Runs forum. We still have some work to do before then though, so you have some time.

 

[Jmeek2004]

Follow this thread, when the time comes we will post a link to the sign-up thread in the Project Runs forum. We still have some work to do before then though, so you have some time.

Setting myself a reminder to keep an eye on this thread. Don’t want to miss this like I did the Obi Wan. You guys are amazing.

 

[Sa1yan5pirit]

Yeah, at this point I'm not even allowed to miss this... Gotta finish the TPM static/accurate collection

 

[Dewy]

UPDATE:

1. Finish scaling exercise and determine overall length COMPLETE 4/8/23
2. Scale “flexible” Solidworks model to final dimensions COMPLETE 4/12/23
3. Complete assembly engineering COMPLETE 4/14/23
4. Use dimensions from #2 to re-model in production grade fashion with assembly features from #3 COMPLETE 4/14/23 & COMPLETED AGAIN 4/16/23
5. Put finishing touches on model (fillets/rounds/chamfers), ensure tolerances allow for clearance for assembly, obsess over the most minor of details, etc. COMPLETE 4/19/23
6. Don’t look at model for 72hrs, then with fresh eyes and mind give the model one final thorough review (this step is key)
7. Send model to Anakin Starkiller for him to do what he does (prototyping and production!)

Well folks, I think I have done about as much as I can do with the model. I have put all the finishing touches on it and I am now at the point where it doesn't feel like I can make further improvements without seeing/feeling something physical. I'm going to officially enter the 72hr hold.

Other than going through all the dimensioning and tolerancing to make sure everything will physically fit together, I have spent several hours focused in on two key areas: the pommel and the emitter section. I really wanted to make sure my model was capturing the very organic aspects of the original prop. It took quite a bit of iteration of the radii of each curve and the angles of each taper to get to the point where I was happy.

 

[Gregatron]

Stunning.

 

[DRambo87]

Perfection!!

 

[Eruonen]

Seeing the TPM Hero Hilts finally coming to fruition makes me absolutely giddy.

 

[BRRogers]

Dewy before you wrap this up I'm giving it as hard a look as I can- I may have a note or two that we can discuss in PM

 

[Dewy]

I have spent so many hours staring at the Obi TPM and QGJ hero saber props at this point. The more I stare at them, the more I think the original masters used to make the black resin pieces were made from wood. Just something about the organic shapes, the way certain corners are rounded, etc. Who knows, maybe they were even originally found items? Perhaps the pommels were ornate wooden post caps/finials like you'd find on stairs or wooden furniture feet. Maybe they were custom made for production and turned on a wood lathe in the same style as decorative/furniture pieces. Just a random thought that's been hanging out in my brain.

 

[DRambo87]

Honestly.... who cares resin, wood, delrin.. these are going to look amazing However, I admire your research and detective skills on that

 

[DRambo87]

Also, absolutely loving the QG model!!