Ok, let me know if this needs to be moved but this project has turned into somewhat of a collaborative effort and it seems like the main place to post updates.
Spent several hours today trying to stitch together reference images to start making the paint stencils. This is by no means done, but here's just a teaser of the main body section where the cone knob is. This turned out way more difficult that I first thought. If you take into account the lightsaber itself is cylindrical, and the photo was taken with a curved lense, and the picture was displayed on a large screen (at celebration) and the photo of THAT was taken, at an angle, with a curved lense, it's easy to see how paralax and foreshortening issues can creep up very quickly. Plus the fact that we don't really have good 360 degrees reference of the prop. With that being said, here is the preliminary layout of the main body section, which I feel is going to be the most difficult. There are a couple of small areas that I really had to guess. Other areas are close but the sizing and spacing is still off. I won't be able to get everything sized and fit correctly until later, when I have all the missing pieces done. But for now here's how it's going. Once I get closer, I'll create a signup sheet in its own thread to order a set of these. I'd also like to wait until I have mine in hand so I can verify everything is perfect and to offer some photo instructions on applying the paint masks.
http://i272.photobucket.com/albums/...6-2004-44C6-93C0-16CBB5902FCE_zpsxjo8jz8k.jpg
http://i272.photobucket.com/albums/...1-04AF-4678-9F75-9FC2961EFC16_zpsnn6grrwg.jpg
http://i272.photobucket.com/albums/...A-6A4C-4BA3-9FAA-9CB2C5425FE2_zpsjpotyphk.jpg