Update time!
Even though I had the saber functioning at CVI, the electronics had a couple of serious issues. First, my attempt to do a custom sound scheme for my wife (which was beyond anything that the "commercial" cards could handle on their own) failed miserably and the result was that Holly had no sound. Second, as CVI progressed, the LEDs continued to get dimmer as the transistor array I was using fried.
I've now completed a complete rebuild of the electronics. The initial version had a small connector tube that was intended to be a sound chamber, and the remainder of the electronics/batteries slid into either side of the hilt. The new version has a full stainless steel chassis that holds batteries, electronics, speaker, and crystal.
[url]http://farm9.staticflickr.com/8501/8295568194_4148fb6809.jpg[/url]
To get everything to fit (Nano Biscotte, Arduino Pro Mini, transistor array, and three constant current LED drivers + extras) I needed to etch a couple of PCBs.
[url]http://farm9.staticflickr.com/8095/8510436861_5c3b8132c2.jpg[/url]
After waaay too much wiring/soldering, everything was in place and working.
[url]http://farm9.staticflickr.com/8246/8550868854_4d7332a9a6.jpg[/url]
Here's a quick video (though I apologize for the quality) showing "Moon River" playing when the NB/Arduino are brought out of deep sleep, "Indiana Jones Theme" leading into the ignition sound, and Toto's "Africa" leading into the retraction sound.
Holly - YouTube