Luke ROTJ V2 lightsaber

Isn't it remarkable how prop masters seem to use the rarest components to build the most iconic props. It amazes me at times. Perhaps that's one of the reasons the pieces become so unforgettable. Do you think the circuit card could have come from a high end calculator? Just a thought. The bubble strip was used from an extracta so the card could be similarly taken from a different model calculator.
 
That sized connector/plug is a 70s thing. During the 80s components shrunk and the 22 pin plug faded away. (13 leads in the clamp means the card were looking for is still rather large) Nothing by Apple is accurate for example. And calculators really never had large plugs like this inside. We're looking for component boards, parts of computer systems from the 70s, those long leads with right angles suggests something professional or industrial.
 
Howdy all,

Bear with me as we talk circuit cards...

V2-ROTJ-05_zpsjipygsoj.jpg


As in Chaim's image, and with feedback in mind, I have widened the traces to 0.1 inches wide, rather than the slightly thinner version I had before. I feel that any other widening of the traces would be in error, due to the foreshortening of the clampcard image, and that the angle it's displayed at is causing us some trouble.

clampcard_v2_04.jpg


The actual THICKNESS on the board of the plated copper is casting a shadow, as well as causing shadow inside the translucent fiberglass substrate of the card itself. With the lighting in that picture, you can almost see a drop shadow underneath the traces, living kind of inside the card substance beneath the traces. Because of the shadowing effect, I believe trace #1 from the left, had its thin trace actuallt proceed further to the left, and was just severed when the card edge connector section was cut from the main board. You can kind of see the shadow effect of this on that trace, as the cut edge of the board follows a contour consistent with the profile of the layers of copper and metal plating on the traces in comparison to the surface of the fiberglass board material beneath.

As to the vias, I believe there are no square vias ( trace terminations ) on this or any other similar board of this era. I point to these examples:

vias.jpg


Note the highlighted traces, as they terminate in small, round circles. Slightly raised, due to the solder flowing into the via, through the board, and to traces on the other side. I believe the lighting of the card in Chaim's images, and due to the fact that we're looking at it from a certain angle, means that the circular shape, and dome of solder is leading us to believe they are more squared.

I am also revising my original opinion that the long wide bars at the top of the clampcard are spacers of some kind, and believe they are just wider traces, similar to the top red highlighted square.

As far as whether or not the vertical traces actually connect to the long horizontal trace, I believe they don't, for the simple reasons that if they did, there wouldn't be a wider via termination circle on the end, and they'd go straight into that horizontal bar. Plenty of examples exist of traces coming VERY close to one another and not touching, and this seems to be the case to me.

trace_proximity.jpg


As far as the top left corner element, whether or not it's a crescent or what, depends on what it was connected to when the card was cut from the main board. I am at a loss to find an example of such a shape on other similar boards.

Also, a note on whether or not the thin traces originate from the center of the rounded thick traces, remember, these boards were not designed by computer, they were most likely hand drawn, as in this case:

trace_inconsistency.jpg


While the thick traces were likely templatized, and standard, the thin ones were most likely drawn in, photoetched, then plated and produced. They might be straight or curved, or whatever the design needed, or the designer felt like drawing.

I welcome any feedback on these thoughts.




Edit:

I also took my layout and perspective matched it to the clamp and card in photoshop, then noticed a few changes that needed to be made.

Here's what I have..

perspectivematched.gif


I've updated the image above to match.
 
Last edited:
We might change the thickness of a thing or two, and nudge some stuff around a tad, but I think we're really close. If I can get within a few thousandths of what we see in the image, I'll be happy. Until a clearer photo of that card surfaces.
 
Thanks for that thorough explanation - it's so hard to talk about these things without the correct vocabulary haha your design looks like you freaking nailed it, at least reasonably!
 
I think you've nailed it with that latest version! Will you be extending the card edge contacts onto the portion of the board that is covered/gripped by the clamp?
 
Looks great Slothfurnace, can't wait to see these become a reality

really appreciate how much work you & the others on here are putting into this

enjoying watching the progress

my current V2 card is a bit of a mess :lol
 

Attachments

  • image.jpg
    image.jpg
    524.5 KB · Views: 212
They'll be a little more than a dollar ;)

Also I went back and set all the thin traces to 0.032, and they seem to fit a lot better...

http://www.slothfurnace.com/images/clampcard/clampcard_v2_05.jpg

http://www.slothfurnace.com/images/clampcard/perspectivematched2.gif


Looking good! Are you sure the stems (I don't know the correct term) get progressively taller and that it's not an illusion from the perspective of the photo? My eyes see that the horizontal parts are more or less level, and your shows the first four at one height, then the 6th-9th slightly higher and the 10th even slightly higher.

I see these as all the same height. I think maybe altering the photo perspective in an attempt to get a "straight on" view might be causing some exaggeration the further they are away.
ScreenShot001.jpg
 
Last edited:
Back
Top