So if anyone is interested I can add end caps and these shroud templates to the kit. Basically stick them onto your sheet metal or aluminum tube and trace/cut.
T'is the season! Luke's Holiday Special lightsaber!
- Thread starter NeoRutty
- Start date
How does one cut aluminum/sheet metal well? I either can't make a cut, or I crimp it to hell.
I normally just use a dremel with a cutting wheel for the big cuts and then a cutting bit for finer cuts. cut proud, then grind/sand flush.
To everyone but you, yes.
Yeah, I suppose that’s an adequate punishment for embracing this ugly saber. I accept your judgement. I’ll be in the Mind-Evaporator if anyone needs me.
LOL! Yeah I'll probably list them separately. Not sure everyone ordering a kit would want the end cap if the existing one works to be filed down and crammed in.
AnubisGuard
Master Member
Dremel and a file if you're patient, tin snips if you're not. I even managed to cut 1/64" aluminum sheet metal with scissors once. (Didn't do the scissors any favors though.)
In either case you'll probably end up with some burring and/or uneven edges that will need filing down.
russellsch
Master Member
I like your sloppy.
WICKED!!!!!
As for the aluminum, after hunting in Lowe’s and Home Depot for aluminum tubing I couldn’t find it
I first thought of sink tube from back in the day building lightsabers. But today it’s vacuum metalized plastic
So once you cut it it will chip and be white..
I tried hard vent for like a drier since it’s already kind bent, but I didn’t have good results and it’s really thin
I ended up going back and just grabbing a small sheet of aluminum .025” thick
I drew some templates up on paper, cut them out with metal sheers, and filed all the edges smooth
Added two little dimples by laying down one of my automotive chisels on the emitter shroud and taping it to make the simple dent
Again the chisel was on its side
I then bend the aluminum over a 1-1/4 black iron couple pipe. It was the smallest and cheapest one at Lowe’s
You need to bend the shroud past the radius of the graflex, because it.. what’s the word I’m looking for.. springs back when wrapping it around the graflex
But if you wrap it around a smaller pipe it springs back to the graflex size and works great
Trent showed me his progress with the patterns, making them a sticker was genius!! Super freak’n easy!! Can I tell you what a life saver his arrows are?!?! Damn..
Can’t wait for him to lock in that bottom end cap, I love it
What I find cool about all this is, I sent him this as a joke xmas gift. Wrapped in lightsaber paper and all, and now he’s gone above and beyond with it. I would have never thought we would have such a accurate control box!! Wicked awesome!!
I first thought of sink tube from back in the day building lightsabers. But today it’s vacuum metalized plastic
So once you cut it it will chip and be white..
I tried hard vent for like a drier since it’s already kind bent, but I didn’t have good results and it’s really thin
I ended up going back and just grabbing a small sheet of aluminum .025” thick
I drew some templates up on paper, cut them out with metal sheers, and filed all the edges smooth
Added two little dimples by laying down one of my automotive chisels on the emitter shroud and taping it to make the simple dent
Again the chisel was on its side
I then bend the aluminum over a 1-1/4 black iron couple pipe. It was the smallest and cheapest one at Lowe’s
You need to bend the shroud past the radius of the graflex, because it.. what’s the word I’m looking for.. springs back when wrapping it around the graflex
But if you wrap it around a smaller pipe it springs back to the graflex size and works great
Trent showed me his progress with the patterns, making them a sticker was genius!! Super freak’n easy!! Can I tell you what a life saver his arrows are?!?! Damn..
Can’t wait for him to lock in that bottom end cap, I love it
What I find cool about all this is, I sent him this as a joke xmas gift. Wrapped in lightsaber paper and all, and now he’s gone above and beyond with it. I would have never thought we would have such a accurate control box!! Wicked awesome!!
If anyone finds a solid aluminum sink tube, mind sharing? Or any 1-1/2 aluminum tube. It would be so much easier that way
This way you don’t have to bang it over the pipe. It’s very hard to bang the small circles “ears” at the bottom of the shroud with out creasing them..
I think I threw away 4 shrouds before I could lock down bending them
Seems like all sink tube today is either brass of plastic.. can’t really think of any other tubing..
It’s tough because it has to be the same diameter and gauge thickness.. not too many applications call for something of this dimension.. and gauge
This way you don’t have to bang it over the pipe. It’s very hard to bang the small circles “ears” at the bottom of the shroud with out creasing them..
I think I threw away 4 shrouds before I could lock down bending them
Seems like all sink tube today is either brass of plastic.. can’t really think of any other tubing..
It’s tough because it has to be the same diameter and gauge thickness.. not too many applications call for something of this dimension.. and gauge
His bought the metal bars used in showers?i bought one last year from Home Depot and started cutting it for a stunt graflex. Sean’s to be the right thickness
I don’t see the metal matching on the real prop. In fact I think the lower shroud piece may be stainless and the top part aluminum.. but again it’s all smoke and mirrors with shading..
That is a good idea though!
Handicap bars?!?
Yea that’s them
Trent and I were talking and I do plan on doing a tutorial with his new stickers and end cap, orientation of the box and black arrows
But I’m gonna need a week. I am remodeling a bathroom for a elderly couple. They only have 1 bathroom in the house, so they went on a cruise so they don’t have to worry about not having a bathroom.
They also asked to install a bathroom in the basement.. I finished the basement bathroom this weekend(no shower) And began tiling the upstairs tonight. Gotta get this bathroom done before next Tuesday..
Once I’m done, I’ll have more free time. But Trent and I do have this in the works.
Just sucks because i have zero time right now. And there’s so much activity on the forum, I’m going through rpf withdrawals
But I’m gonna need a week. I am remodeling a bathroom for a elderly couple. They only have 1 bathroom in the house, so they went on a cruise so they don’t have to worry about not having a bathroom.
They also asked to install a bathroom in the basement.. I finished the basement bathroom this weekend(no shower) And began tiling the upstairs tonight. Gotta get this bathroom done before next Tuesday..
Once I’m done, I’ll have more free time. But Trent and I do have this in the works.
Just sucks because i have zero time right now. And there’s so much activity on the forum, I’m going through rpf withdrawals
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