there's been a lot of talk about it on thebhg forum (as Pre Vizla wields it)
the licensed version dimensions are as follows (from tk3181) :
Hilt length:12-1/2"
Pommel to Tip of blade: 34-3/4"
Blade from emitter to tip: 22-1/4"
Height of blade at tallest point: 1-3/8"
Width of blade: 1/2"
Width of hilt: 3/4"
Height of hilt: 1-1/4"
your main job would be to make the hilt first.
machined if you have the facilities, though there may be other options. Just want to keep room in it for some electronics
you obviously can't make a light thats black but you could perhaps have a black blade that's clear around the edges showing white through like it does, perhaps a cracked or mottled effect on the black so it shows imperfections (cracks of light shining through)
you'd need some plastic moulding skills I would have thought in order to make the flat blade, or perhaps a solid bit of acrylic, painted how you want. might be heavy though.
check out fx-sabers, a few people have done them.. there's even a sound font floating around if you add a sound board to it
