It is an interesting theory, and I was just wondering what to use for the brass plate under the clip for my build. I have plenty of 2 cells lying around so I might sacrifice one for my build as well.
However, the disc is clearly not such a "perfect circle" like yours but it is quite roughly shaped. I think it could happen if they used a file (or a dremel, etc.) to roughly file off the rim/lip section by section (as much as the file width allows) and filed some sections too much. What is visible from the rim under the plate does not look unevenly filed though, but they could have cleaned it up a bit before assembling.
But how is the plate attached back to the flash? Could be the rivets go all the way through the clip, brass plate and into the supposed core inside the flash (but should have really long heads for that)? Or the rivets just hold the clip to the plate and the plate is maybe glued to the core?
And one last observation (or two). What's visible from the rim looks to be still chromed (although, could be painted over like the disc itself). The brass plate at least at one section appears to be over the rim on both sides. If it was the disc from the flash - the rim should have been brass, and the plate can't be with a larger diameter than the inside of the rim (unless the tube was slightly damaged and deformed into oval rather than a circle, but it does not look like it).
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So, on the OTHER end of the saber I made some headway.
It looks like the endcap is screwed up on Dagobah. For sure it's screwed up in the 90s during the Magic of Myth tour, and that means most likely it was during Jedi filming. If IronDestinyProps doesn't mind, I took his photo of a recent project, cropped the real prop comparison and boosted the contrast to show what I see.
I have always seen a very thin rim around the endcap. That is.... underneath what I will call the "kobold plate"
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So in essence... I see it in layers
1) Thin Graflex wall and filled endcap space
2) Kobold Plate and a washer? near the center
3) Kobold D ring and possibly the original rivets, lathed down
I have never been able to fathom how the wall could be so thin. The Graflex itself is almost 1/16" in thickness and then today.... an idea struck me. Where is the graflex wall thinner? Why... where it's milled for the endcap to sit! I sacrificed a 2 cell bottom to learn about the cross-section myself. Sure enough, I found a lip thinner than T track.
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At this point the Graflex started to look like the DV6 but I couldn't find the seam-line of the endcap and wall!
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so I dropped one of my metal files, handle down in there, and whacked it with a wooden mallet. The cap fell out.
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I almost think they put the endcap back in place. Maybe upside down? Maybe the hand-cut "kobold plate" is the original endcap but flipped? I'd love to hear people's thoughts
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Thank you! Yes, the skywalker ranch belt hanger still has its endcap, and we can really see the difference between that and the missing lip on the bladed one!
Could be! Wouldn’t we see a shadow going down into the top all the way instead of that weird cone shaped shadow?Can’t say I see a gap anywhere here…
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I really like Alleys alternative with the brass hollow tube
Some times in my automotive experience when hammering these in, the pinch so hard, and then the elements get in there, i sometimes I don’t realize it’s a roll pin until the other side starts coming out and I see the seamThank you! Yes, the skywalker ranch belt hanger still has its endcap, and we can really see the difference between that and the missing lip on the bladed one!
Could be! Wouldn’t we see a shadow going down into the top all the way instead of that weird cone shaped shadow?
Actually, what I'm seeing that is interesting is that the lip looks ground down a bit on the ranch saber in a similar way to which your 2-cell looked when you started machining off the lipThank you! Yes, the skywalker ranch belt hanger still has its endcap, and we can really see the difference between that and the missing lip on the bladed one!
Oh my gosh, great eye! Yes… it looks like when I just started to grind the lip. What the heck were they doing?Actually, what I'm seeing that is interesting is that the lip looks ground down a bit on the ranch saber in a similar way to which your 2-cell looked when you started machining off the lip