I have redesigned everything. Now the sleeve is 38mm (1.5") diameter so everything has been redesigned from scratch, not simply a scale down (except for the pommel). I have already ordered from Shapeways the pommel with the last mods and I'd have it by early next weekend (05/19 probably). I'll post some updates then.
KaanE, I'm not very familiar with the details of this saber, but your rendering skills are great!
The saber looks very cool. This whole time I thought that black part was leather or padding or something. I can't wait to see your full saber, man.
I received the pommel and had the other pieces redesigned. The pommel is really nice and exactly what I was expecting. The only problem is that I'm out of budget for a few months and won't be able to buy the other parts. I'll try to post some good pictures of the pommel later today.