Kyle Katarn Saber - PVC build

[division 6]

After years of putting it off I finally made myself a Dark Forces 2 lightsaber.

Made from PVC, Couplers and Epoxy Putty.
I did up blueprints based on the easily found illustration that is very close to the cut scene prop.
I also added details seen in the cut scenes like where Kyle first gets the saber and at the end when it's destroyed.

I plan to eventually make another one with a somewhat different construction method.

 

[Jedi Reali]

That looks awesome! Care to share painting/weathering tips?

 

[Blue Leader]

Awesome stuff. Canon or not, Kyle is still one of my favorite characters.

 

[clancampbell]

That is a REALLY nice build! One of my fave sabers too! The design makes a mockery of all those machined prequel monstrosities, top work!

Rich

 

[Probe Droid]

That's pretty sweet! Bravo!

 

[division 6]

Thanks guy's.
Definitely a cool saber.

That looks awesome! Care to share painting/weathering tips?

I used Duplicolor Automotive lacquer for the primer, silver and semi gloss black.
Black base, then silver, then black on the detail areas.
Rust-oleum metallic gold.

Weathering through the black was done by sanding with 600 grit wet sand paper.
Then weathered with Liquitex acrylic paints.
Burnt Umber, Raw Sienna, Raw Sienna mixed with Titanium White and Payne's Grey.

Paint on, let sit a few minutes, then tamp off with paper towel then with damp cloth, repeat for each layer until desired look is achieved.

Accept for the "screw divots" the entire thing was made entirely with hand tools.
Pipe cutter, Exacto knife, razor saw, files, sand paper.
Dremel with grinding tip was used for the divots.

The D ring is held on with a strip of thin brass.
End cap dome is a plastic bubble from those things out of a gumball machine.

 

[JoMamma_Smurf]

I've been looking to buy an accurate Kyle Katarn saber for years!!!

 

[Naxu]

Sweet, looks good


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[DeathlyTaco]

Very Nice build

 

[Matakin]

I've been looking to buy an accurate Kyle Katarn saber for years!!!

There's a guy on fx-sabers forum selling run of empty Kyle Katarn hilt.

 

[The Schlitzie]

The paint job and weathering sell that saber! I would have never known it was pvc. Great job.

 

[Darth Lars]

That's some heavy weathering. I'll have to watch the cut-scenes again.

This saber has long been on my list of things I wanted to do, but couldn't justify having in my collection...
I thought there was supposed to be a piece of cylinder covering a side of the top details...

 

[division 6]

Thanks.
I have some Rey pack parts for my niece that I weathered while working on this the look like dirty, rusty metal also.

Smurf,
Most if not all replicas (and blueprints) I saw looking for info have added details that are not present on the actual cut scene saber.
Usually extra grooves or grooves that are to wide, metal plate going over the left side (have no idea where that came from), screws on top, brass top rail with rounded end, different interpretations of the grooves, etc.

I used the illustration since all the dents, etc matched the actual prop.
The scene where it's destroyed it's missing the switch and lower strip (possible where the idea of the side plate came from) and has the screw hole on the left very visible.

 

[division 6]

That's some heavy weathering. I'll have to watch the cut-scenes again.

This saber has long been on my list of things I wanted to do, but couldn't justify having in my collection...
I thought there was supposed to be a piece of cylinder covering a side of the top details...

I weathered it more like the illustration to make the details pop.
I couldn't find any real evidence of the tube/plating on the left side.

 

[division 6]

This is what was used accept I ended up using Aves epoxy putty since I still had enough for this piece.
Not pictured is 1/16" thick sheet styrene, plastic dome, D ring and brass sheet to hold it in place.

When I get around to doing a second one I'll take actual construction pictures.

 

[JoMamma_Smurf]

I would pay you to make one of those for me

 

[Kylash]

Man if you did a resin run of these I would be soooo in. I cant believe that's pvc!

 

[Jedi Reali]

When I get around to doing a second one I'll take actual construction pictures.

I'd love to see a build thread on this if you do another one. I don't have the ability to work with metal, and I'd like to give something like this a try with plastic. I'm sure I'd benefit greatly from seeing how other people do it.

 

[Jonbre]

This looks absolutely fantastic! This and Yun's yellow saber are my favorite from the Dark Forces series. This saber has so much character!

I'm also all-in if you choose to do a resin or 3-D print run of these! Fantastic work!

 

[division 6]

You guy's are too kind.

It's actually straight forward and fairly easy to make.
And the best part it's cheap.

I did all the beveled edges with the epoxy putty, with the next one I'll dremel the edges to save time on sanding.