The OT stunt lightsaber blades research thread

[Mouse Vader]

BTW I'm not of the opinion that it can't be a whip antenna. What I do have concerns about that they seem to be hollow/tubular copper cored, all be it enacse GRP. My concern is crushablity. These things may be very flexible & bendy but that's not the same as taking an impact from / on a relatively small sectioned equally hard object. The impact side has the interior space to deform into so the actual compression strength is only in the wall thickness & not the full diameter. Conversely solid GRP doesn't have this problem. What it wants to do is 'green stick fracture' if the tensile strength is exceeded across the back of impact area (opposite the striking object). Unfortunately this just leaves us with option buying examples of each & testing them. I can get a 5/8 straight 1m GRP rod for about £13 over here. I will do so & see how difficult it is to drill, if someone can provide some sort of diagram of believed base construction.

 

[thd9791]

Awesome - you're right, that's sort of what happened with aluminum in the Prequels, it just folded

So, looking at the ROTJ MoM saber, there are tangs that are a little less than 3/8" and grooves lathed in for a set screw. Metal collar of around 1or 2 mm thickness around the outside/base of the blade and a metal collar inside. This would be the left over space between the tang and inside of the blade material, whatever it ends up being.

I would say the outside collar is 1-2cm tall or long. God knows the inside length

 

[thd9791]

I had just enough Scotchlite to coat my 2 PVC sparring blades.

I actually used Mouse Vaders method of starting by covering the end and pulling the fabric down, wrapping it and snipping off the "ears"

I actually gaff taped newspaper to a wall and gaff taped my fabric to it. I just used the stock width, this was a lazy test and something to help me learn how to smooth fabric into place, a little practice, so i did away with other variables.

I got minimal wrinkles, most came when i lapped the fabric. If i had snipped the fabric to the right diameter it would probably end up flawless. Didnt scratch my hands this time, i almost wonder if it was a raw factory problem with this roll or if i imagined it.

Anyway, no taper here either, just a straight cylinder, but i imagine id be snipping a triangular flap along the length if it were.

3M Scotchlite fabric is so strong. If i were working with it professionally i would be happy relying on its reflectivity. It almost blew out my camera phone from 5 feet away.
I dont know if colored graphic film reflects a color? The fabric at least only comes in this finish. If we find blade material maybe ill have one white and one colored blade for all my stuff

Handles are just a section with Gaff tape on it from my first videos

Last is reflexite tape in the center

 

[thd9791]

Soooo Scotchlite reacts to light filters. I used the switch lens from the X Wing control pad. Also, beginning of the video the flash is covered with Gaff tape and enough light got through it changed it again

 

[Propdude113]

Soooo Scotchlite reacts to light filters. I used the switch lens from the X Wing control pad. Also, beginning of the video the flash is covered with Gaff tape and enough light got through it changed it again

Very cool!! It just goes to show you, practical effects are ageless

 

[Mouse Vader]

I actually used Mouse Vaders method of starting by covering the end and pulling the fabric down, wrapping it and snipping off the "ears"

Nice to see my efforts aren't wasted. I also wasn't able to be entirely wrinkle free & having watched so much footage of ANH blades I strongly feel this is 'authentic', at least for much of the time. I'm sure with repetition we'll get fewer of them. Could also suggest haste by the props guys.

Your pic's are great examples of how much 'flare' / overexposure scotchlite produces making the blade look nearly twice as thick. Nice red effect you got with that red lens. This was also tested in ANH pre-production using 'gels' (colured acetate sheet) as demonstrated in my ref clips VC1 & VC3 on my ref thread : The ANH LightSaber Blade Reference Thread
This is test footage of the static 'ice-cream cone' type (VC1) &, I believe, of motorised square blades (VC3).

 

[thd9791]

I found a better resolution version of the ESB photoshoot pic. It looks like Luke's saber doesn't have a bunny ear ring, or is a pipe saber. ANH Stunt or a Graflex I'm guessing because it has T track? Vader is holding a real MPP Stunt.

 

[Halliwax]

I found a better resolution version of the ESB photoshoot pic. It looks like Luke's saber doesn't have a bunny ear ring, or is a pipe saber. ANH Stunt or a Graflex I'm guessing because it has T track? Vader is holding a real MPP Stunt.
View attachment 1297322

Really strange... I see weird stuff where the side sockets would be.. what’s going on there?!

 

[thd9791]

Really strange... I see weird stuff where the side sockets would be.. what’s going on there?!

Looking closer, I do see a recess. Like, I think the saber bevel is facing us so the socket would be right there. It's possible it is this saber

 

[Propdude113]

Just now catching up on posts. I recently watched the Skywalker Saga documentary. And viewed Halliwax's post in his weird v3 theory thread for close ups on the v3.
Watching Bob Anderson and Mark Hamill spar the blades look super thin in spots. I am talking super thin. Is this just a camera glare? Could it be they used steel fencing foils? possibly thicker versions. I know that pirate and old era films use prop swords made of spring steel and aircraft grade aluminum they don't seem to bend could this be a possibility? Even in tube form? Or could it be some different composite material? Only thing I can think of is fiberglass or carbon something? maybe a metal something? Breaking fiberglass fishing rods isn't yielding any results for me LOL

 

[Halliwax]

Soooo Scotchlite reacts to light filters. I used the switch lens from the X Wing control pad. Also, beginning of the video the flash is covered with Gaff tape and enough light got through it changed it again

just seeing this now, she's damn good at that! better watch out, i think next duel she'll take ya!!

 

[Halliwax]

So I don’t know if this is a appropriate place to start this.. but since the most of us who are obsessed with stunt blades are in here I figured I’d ask

If it’s not cool, I’ll delete this

But I was talking with Tom the other night about blades. I got the idea of having my friend who makes carbon fiber hoods, fenders, doors and wheel wells for race cars.. trying to get him to make us custom made stunt blades

My plan is to 3d print a master and have him use that to mold a master and make the blades for us

What I need is us all to agree on the actual dimension of the blade. This way I can model something and print it

I asked him awhile ago to make me one but he was reluctant because it was too much work for 2-3 blades.. but if we can get a bunch of us in on this we might be able to convince him to do it

Just throwing this idea out there.. if we can get a consistent blade. I can do a run of nipple/collars for them as well

 

[PrinceZip]

Hey folks!
I'm not an expert researcher of OT stunt blades,
But I do have photos taken from the archive that shows real close-ups of the blades, blade base attachments, hilt cores, as well as cross sections of the blades themselves.

Not sure if I can go into detail, but I can tell you guys the blades are composed of a few different materials.

 

[vadermania]

So I don’t know if this is a appropriate place to start this.. but since the most of us who are obsessed with stunt blades are in here I figured I’d ask

If it’s not cool, I’ll delete this

But I was talking with Tom the other night about blades. I got the idea of having my friend who makes carbon fiber hoods, fenders, doors and wheel wells for race cars.. trying to get him to make us custom made stunt blades

My plan is to 3d print a master and have him use that to mold a master and make the blades for us

What I need is us all to agree on the actual dimension of the blade. This way I can model something and print it

I asked him awhile ago to make me one but he was reluctant because it was too much work for 2-3 blades.. but if we can get a bunch of us in on this we might be able to convince him to do it

Just throwing this idea out there.. if we can get a consistent blade. I can do a run of nipple/collars for them as well

Are you talking of stunt blades that could be used for stage fighting, or just for display? I wouldn‘t actually duel with a carbon fiber blade unless it is covered with some sort of soft plastic material (like the shrink wrap material they used on the ROTS stunt blades, I have one of them right in front of me now).

 

[thd9791]

Not sure if I can go into detail, but I can tell you guys the blades are composed of a few different materials.

Are you allowed to confirm if the blade itself is multiple materials, or the whole rig is?

I talked to someone else who discussed these as composite things and that was because there was a handle, handle decorations, core, collar/nipple, blade, blade coating/wrap, etc. and those are technically all different materials.

I will also say I hope my projects have been in the ballpark of what you see at least lol

As for blade diameter, the ESB Bespin blades have to be around 18 MM at the base. The taper is hard to define from our reference. It's hard to describe, but the base of the Bespin blades cover a certain amount of the Graflex, and 16 MM tube doesn't cover enough. Like I shouldn't be able to see the bunny ear cut-outs at all

 

[PrinceZip]

Are you allowed to confirm if the blade itself is multiple materials, or the whole rig is?

I talked to someone else who discussed these as composite things and that was because there was a handle, handle decorations, core, collar/nipple, blade, blade coating/wrap, etc. and those are technically all different materials.

I will also say I hope my projects have been in the ballpark of what you see at least lol

As for blade diameter, the ESB Bespin blades have to be around 18 MM at the base. The taper is hard to define from our reference. It's hard to describe, but the base of the Bespin blades cover a certain amount of the Graflex, and 16 MM tube doesn't cover enough. Like I shouldn't be able to see the bunny ear cut-outs at all

I can confirm that the blade itself is made up of different materials.
Imagine a thin roll of sushi, except metal and other weird stuff lol

This multi-material composition is probably why the blade is sturdy, reflective, spinning, making "clank" sound at the same time.

Most of the other parts like the hilt core and "nipple" appear to be aluminum,
But I'm still not sure if they are found parts or custom made.

 

[thd9791]

I can confirm that the blade itself is made up of different materials.
Imagine a thin roll of sushi, except metal and other weird stuff lol

Why thank you sir!

 

[Halliwax]

Are you talking of stunt blades that could be used for stage fighting, or just for display? I wouldn‘t actually duel with a carbon fiber blade unless it is covered with some sort of soft plastic material (like the shrink wrap material they used on the ROTS stunt blades, I have one of them right in front of me now).

Not for dueling just for show

 

[Propdude113]

I can confirm that the blade itself is made up of different materials.
Imagine a thin roll of sushi, except metal and other weird stuff lol

This multi-material composition is probably why the blade is sturdy, reflective, spinning, making "clank" sound at the same time.

Most of the other parts like the hilt core and "nipple" appear to be aluminum,
But I'm still not sure if they are found parts or custom made.

So multiple materials with a possibe thin outer metal shell? VERY interesting

 

[Mouse Vader]

This multi-material composition is probably why the blade is sturdy,

I take it these aren't ANH era. We've heard so many times from various sources ANH blades were fragile, at least for dueling with.

Roll of metal eh? anything similar to this? (I know this is much larger diam.)( I also have a steel one & plastic one I was going to make into a saber blade for switch on effect.)

& thanks for the new info. Always welcome.