<div class='quotetop'>(Zenkai @ Oct 22 2006, 08:50 PM) [snapback]1342825[/snapback]</div>
Yes, the collar does have a chamfered edge on the side closer to the grips.
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How do you know the edge is chamfered?
Anyway, there is another detail that you have missed. Below the edge, the sleeve is narrower, as if metal had to be ground away to fit the collar onto it, just like metal had to be ground away from the neck above it.
This detail can be see in most reference pics of the Hero, but not very much in the pics of Anakin Starkiller's resin stunt.
<div class='quotetop'>(Zenkai @ Oct 22 2006, 08:50 PM) [snapback]1342825[/snapback]</div>
The emitter plate is flat with a 7/8" hole, at the moment. If I produce one, it will likely remain this way.
Not sure which of Starkiller's pics you're referring to, but I believe I've got all the details in there.
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Cool that you are making this one fit a blade.

I'm referring to the underside of the emitter plate, as seen from inside the emitter grooves:
Here is the pic I am referring to. You can see that there is some room inside the chamfered "keyhole plate".
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Just to make sure: Are you sure about all the main dimensions? Have to got them from a reliable source?
I am a little bit curious about the length of the thick section that the covertec button is attached to. That one in particular is longer on the TPM Hero than on the MR AOTC.
It would be interesting to discuss how you would build the saber, also.

You could easily fit 3 rechargable AA batteries in the inner silver tube and pommel. 3×1.2 = 3.6V which would run a Luxeon K2 well. The LED with lens and holder would fit but the prewired PCBs are too large.
Edit: Why does the pic not show? It shows in preview but not in the thread... Do I have to put it in "quote" tags?