Hardware version of Mara Jade's lightsaber?

[jason1976]

Well, Mara's has long been one of my top 3 favorite lightsabers. (the parks style, though I like some of the other makers versions of it better) It's near the top of my list of most wanted props.

Unfortunately, it always goes for WAY more then I can afford. So, I'm once again considering doing a hardware version.

I'm open to any suggestions at all on this project, but I'm specifically trying to find the simplest way to do the lower grip. (the bit with the 12 bolted on meal strips.)

I don't have a lot of skill, or equipment, but I want this to look as close to the real thing as possible. (boy I don't ask for much, do I? :lol )




Oh, and If you can't help with a hardware version of this saber, , my B-day is coming up in october, and I do except gifts.

 

[Darth Lars]

It consists of pieces from an outer aluminum tube that fits onto an inner aluminum tube. I'm thinking, maybe you could take advantage of the fact that the pieces have bolt holes.
Here are some suggestions from the top of my head, there might be easier methods.

Method 1:
1. Make a template, glue it around the outer tube, drill the holes and cut to length. Then bolt the outer tube onto a scrap inner tube.
2. Cut the lengthwise grooves thinly with a dremel cutting wheel - does not have to be all the way through, and should not be the full width.
3. Remove from the inner pipe and cut one slit through. Bend off the pieces. Edges don't have to be perfect.
4. Bolt each strip to a piece of steel rod that has the correct width. Go at the edges with a file. After this step for all 12 strips, you should have nice strips.

Method 2: If you have access to a band saw or miter box that allows you to split the outer tube lengthwise in two identical halves.
1. Like 1 above.
2. Cut the 12 slits with a band saw or hacksaw+miter box, but only half-way. You do this in six cuts, two slits in each cut.
3. Remove from the inner tube, turn it around and bolt it to the inner tube from the other side. Cut the slits from the other side.

Of course, you could have started with flat strips with the correct width, but flat grips would not be as nice.