The emitter rings and the black grip both slide into outer shrouds, and if the black paint is too thick, it might get scratched and/or not fit inside. (I know this from putting together my own OWK Ep1 saber ...)I wouldn't do anodized aluminum. If I did aluminum, It would be raw and buyers would paint it.
thank you for the detailled explaination, that's nice to read.I wish I could, but my stunt saber has some damage to the pommel and and the seam had some misalignment when they pulled it. There's too much shrinkage and distortion with each molding, it would be impossible to get consistency in the castings that would work with a machined aluminum sleeve.
The reason why I do delrin is to get as close to the original material as possible while still maintain a high degree of machining accuracy. It actually gets us closer to the original then a resin casting off one would
after the machining... looks like the powder coating on the pommel.
* still not as hard (easily scratched) as AL.. but looks good.