Gary Kurtz Graflex lightsaber making process

mosseraiser

Member
Hello everyone, this is my first public post on the RPF and I am happy to share my GARY KURTZ graflex making process with you guys!

【Having shown up in a couple auctions, ANH and ESB pro - ducer Gary Kurtz has parted with some lightsabers from his personal collection. While billed as being used in the film, evidence points to the fact that they were never seen on - screen.】(by roy 《light saber guide》)
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(Picture from roy ,《light saber guide》)

Firstly this lightsabre resembles a hybrid in that it has rounded corners like anh on his grip and secondly it has tfa style riveted fixings.
Its grip is different from the normal t-grip and I observed that it is about 1mm higher than any normal grip. And the top of the grip is flat. So the best thing to do is to 3d print.
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After a few more rounds of failed print attempts, I think I got a result that I was happy with.
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I started with a base coat of black filler, followed by a coat of mr hobby's red paint, and a coat of protective paint.
After that it was time for the black lacquer, and when they were completely dry some of it was wiped off, leaving the red on the edge of the grip.
As the material of the grip is resin, I do not recommend using a rivet gun to fix it directly, but to remove the head and glue it.

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The clasp on the back cover is different from a normal clasp, I assume it is a piece of metal iron. But I opted for the most time efficient method which was 3d printing.
In the area marked in red I noticed a chamfer here, I'm trying my best to restore them through my 3d model.

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And try to adjust the size.
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Give it a nice lacquer finish.

Regarding the d-rings it is also unusual. It is smaller than the usual graflex ones and larger than Luke's v2. Luckily I had a mpp shrouded d-ring to hand to use and I tried bending them to get the desired size.
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Here is a demonstration of the final result!

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I used the original graflex inc upper half and clips, the lower parts I used are accurate replicas from KR sabers. Thanks for watching!
 
Here is the 3d stl file of the above grip and loop which I am happy to share with you guys.
If you guys don't mind that it may not be screen accurate enough><
They are ready to print and just need a simple sanding down of the edges to be painted straight away.
 

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Love the build!
Liking the worn red grips!
I have read some of the back story about these but do we know why red grips were used ?


Mott.
 
Nice work - those grips look exactly like the weird ones on the Kurtz saber… 3D printing is amazing sometimes - you nailed the red tint too.

The back end… I’m pretty sure they took extruded aluminum flat bar and cut it to make the D ring block. That squashed look sometimes comes on the edge of flat stock. The groove is interesting, I wonder if they were just mapping out where to drill the rivets and scribed a line
 
Love the build!
Liking the worn red grips!
I have read some of the back story about these but do we know why red grips were used ?


Mott.
I haven't researched too much as to why they use the red grip, I like the look of it. But as well as whether the lightsaber was actually made by the prop team or not is open to question.But if it was indeed made by Lucas' prop crew, then my guess is that perhaps they couldn't find any more T-tracks and carved the grip out of some other material, as there are observations of some of the angles coming from filing in the rounded sections. This material may be mahogany.
 
Nice work - those grips look exactly like the weird ones on the Kurtz saber… 3D printing is amazing sometimes - you nailed the red tint too.

The back end… I’m pretty sure they took extruded aluminum flat bar and cut it to make the D ring block. That squashed look sometimes comes on the edge of flat stock. The groove is interesting, I wonder if they were just mapping out where to drill the rivets and scribed a line
thanks for your words
Yes, they should just use extruded aluminum. For that one line, it looks to be between the two rivet ports. But if you pay attention to the picture of origin prop you will see that the left end of the line is deeper than the right end. The cause of this could be that they intended to separate it with a cut metal cutter like Paper cutter but that didn't end up happening. This is just a guess on my part.
 

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