Obi-Wan Kenobi Episode 1 Resin Stunt Lightsaber Research

These look awesome! I've always wanted to know how they did these props. How did you get the m10 coupler to stay inside the metal blade? I was wondering if that's what the set screws were meant for

Another day another clean pull. The right most saber is fresh out of the mold with zero cleanup:

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And I think I found a green I like:

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Another day another clean pull. The right most saber is fresh out of the mold with zero cleanup:

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And I think I found a green I like:

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Interestingly I’ve found it more likely the screws went all the way though. It helps keep the blade from unscrewing and quite frankly there are very few threads within the aluminum wall.

I sized mine at like … M5 or something and there’s 1-3 threads by guesstimate in the wall of the tube. And it’s a tube so some of those threads are incomplete.
 
Testing paints, this was just some silver metallic I had on hand, definitely not it:

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The paint went on smooth enough, what looks like a rough texture in the pictures is the insane amount of metal flake in this rustoleum silver metallic. It looks glittery!

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I have some Tamiya acrylic lacquers on order, won’t be here until next weekend. I might head to Home Depot/Lowes to see what non-Rustoleum options they have.
 
I will say, it is really interesting to see what details get lost/altered in the casting, sanding, and painting process.
 
Used some Markal paint markers for the red button and brass knob, actually came out pretty good. I think if don’t go quite as heavy next time, the metallic silver will show through the red/gold and give the semi-metallic look that some of the production resin stunts have.

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A lacquer paint I like using for an aluminum look is Dupli-color BFM0226 Silver Metallic in thin coats over Dupli-color black primer (just enough coverage to where you can't clearly see the primer). It goes on super smooth and the flake is fine enough that you don't get the glittery effect.

I think it might work well for the prequel sabers too - particularly when applied to full opacity as it will come out brighter.

The silver parts of this saber are painted with the above method (the booster/grip/pommel parts without foil tape):

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Right - how well did the black hold up to painters tape? I've had paint come up from the resin when trying to mask off parts for a silver top coat
 
Right - how well did the black hold up to painters tape? I've had paint come up from the resin when trying to mask off parts for a silver top coat
My process: After cleaning up the mold lines and some of the bubbles on the raw casting. I washed the thing with Dawn dish soap, and sprayed it with Rustoleum Gray Sand-able Primer. Since I wasn’t really testing the black paint as much, I just used two coats (1 light, 1 heavy) of Rustoleum Satin Canyon Black and waited until it was dry to the touch to apply yellow frog tape. I definitely didn’t wait long enough for the black to dry, so the paint did lift up a bit, but not all the way to the primer/resin.

To my surprise the satin canyon black actually looks pretty close. It has that thick glossy appearance. I always thought the black paint looked like the prop was dipped instead of sprayed. Not that they actually did that, but that it LOOKED that way, and I think this captures that. I have some other black paints on the way to test out though.
 
A lacquer paint I like using for an aluminum look is Dupli-color BFM0226 Silver Metallic in thin coats over Dupli-color black primer (just enough coverage to where you can't clearly see the primer). It goes on super smooth and the flake is fine enough that you don't get the glittery effect.

I think it might work well for the prequel sabers too - particularly when applied to full opacity as it will come out brighter.

The silver parts of this saber are painted with the above method (the booster/grip/pommel parts without foil tape):

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I picked up some of the silver you recommended and their gloss black. So far I have done two coats of the gloss black over regular Rustoleum gray sand-able primer and it is looking VERY good. It has just the right sheen. I’m not sure how to describe it, but it reflects a ton of light, without having a clear reflection.

I went to do a test spray of the silver, and it came with a dud nozzle. More sprayed back at me than sprayed towards my test part. These Duplicolors are acrylic lacquers and my local auto parts store had probably 7 different variations of their silver, so I’m optimistic I can find one that will work. Until then I’m going to borrow the nozzle from the black can to paint this one silver:

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If you zoom in on my above picture, you can see the black even has a slight texture, despite going on resin/primer that was sanded up to 600 grit. You can also see distinct light reflection without a clear shape. Both of these qualities match the stunt sabers. For comparison:

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I hate to keep spamming my own thread, but I’m using this somewhat as a notebook that I can later reference. Along those lines, we’ll see how it looks when fully dry, but:

Duplicolor Perfect Match Universal Gloss Black (BUN0100) looks like a good match for the QGJ hero black parts, which are not as flat black as the Obi TPM hero black parts.
 
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