Hi guys,
I've read through this and tried to digest as much as I can.
The diagram a few posts back showing how the emitter is held on via the rod is generally accurate. It's been some time since I disassembled the prop, but I'm pretty certain the nipple and the emitter are one single piece - this is evidenced by looking at the shaft that runs through it -- there are no breaks in that shaft.
I have never known exactly how the motor and blade set up for ANH worked. I don't know how it was set up. I don't think anyone does - though we can speculate. Certainly the emitter spins freely now and based on that I assumed it did at the time of ANH - could be wrong, as evidenced above. It's possible that a shaft originally connected to the motor in the hilt and extended out through the emitter - the emitter could have been free floating on it, and thus not spinning in some shots. Nobody knows.
I don't think the emitter was ever cut or anything like that. The emitter neck fits cleanly into the neck of the hilt itself -- they are made to fit together. This feels very intentional. Also, I don't see any evidence on the "V2" (I've never understood the name...) of it starting as a cast piece. They may have tried the cast piece ("V3"), found it didn't work very well, and gone to a straight machined piece instead.
I have always believed this was the prop used by Guinness in ANH. See the strange long clamp lever, that has not been seen on any other prop, and the missing Graflex sidebar. The jawa stun-prop is interesting -- could well be the exact same clamp. I note that prop is in Tunisia, whereas the saber prop would have been filmed later, at the studio.
Some unknown / undocumented additional hilt being the actual one used by Guinness? I'll leave the door open that anything is possible, but I doubt it. They didn't have many multiples on props for ANH. Look at the other key hand props...
Why are there two sets of set screws on the emitter - one below the widest "Emitter plate" and another on the nipple? I can't answer exactly. The ones in the nipple position, as it sits today, in to a groove cut in the run, and that's what locks the emitter on. I don't know what the lower set is doing, or did, if anything. It would seem reasonable that the lower set might have locked the emitter to the hilt, while the upper set somehow locked the blade in.
When I first saw the saber collars on the real blades, my immediate thought was -- the nipple on the hilt is one of those. But when I looked, they are different. The nipple on the Luke saber is a two-step thing. The collars on the existing saber blades don't have that step in them. It's also quite likely IMO that the existing blades are from ROJ only, possibly ESB, and most likely not from ANH.
If the footage truly shows the nipple moving and not the emitter face, it must be a different emitter, at least, to this one. Perhaps the "V3" was used for some shots.
I always welcome research and information. Unfortunately, we may never know exactly how the ANH blade-to-motor connection was made.
BTW, slightly related, check out the footage at around 8:03 here:
Is Hamill spinning the blade freely on the hilt, as it does today? I always thought it looked that way.
Best
Brandon