TrooperTrent Holiday Special Lightsaber Series

Discussion in 'Star Wars Costumes and Props' started by halliwax, Feb 18, 2019.

  1. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    TrooperTrent's Holiday Special Kit

    PJvnIGv.jpg

    A lot of information has been discovered in the links below. These threads should be consider a archive for the Holiday Special
    _________________________________

    Neorutty's HS thread
    Paul Duncan Archives book


    _________________________________


    INDEX

    Part 1
    -Dissasembly of the flash, tung mod and thread removal

    _________________________________


    You can purchase these kits here!
    www.etsy.com/shop/troopertrent

    _________________________________

    UPDATES
    - 2/18/19 Released Disassembly video
    - 3/6/19 Released Control Box video

    Video Series Tutorials

    2/18/19 - Episode 1 Disassembly of flash, Tung fabrication, Thread Removal

    2/23/19 - Episode 2 Shroud Fabrication




    Material / Parts / Paint
    _________________________________

    TrooperTrents Holiday Special Kit
    Korbanth T track (or track of choice)
    Aluminum Sheet (shroud)
    -
    - Rustoluem Flat Black 7578
    Blue Painters tape
    E6000
    _________________________________

    TOOLS

    Aviation Snips
    Tweezers
    Semi-Large Drift/ Nail set (nostril punch)
    Mini Clamps
    Hammer
    Mini-File set


    - Flat head screw driver
    - Dowel
    -Chop saw/miterbox hack saw
    - Sharpie
    - Mini file
    - Nail set
    _________________________________
     
    Last edited: Mar 6, 2019
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  2. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    Welcome to our next new project series! TrooperTrent came to our rescue once again, now with this cool replica of the Holiday Special lightsaber! this next series of tutorials will cover everything you need, and the steps you have to take to get your Graflex 2773 to the highest level of accuracy!!

    So first lets disassemble the flash, and do a few little mods! To begin the easiest thing to do is take some reference pictures of the 3 small screws we have to remove and 2 large ones. the 3 small screws, 2 are the same, and 1 is different to remember where the different one goes.

    Screw 1
    toSdNt5.jpg

    Screw 2 is located on the other side, below the "tung pin" we will get to the tung pin soon!
    ql4wlEa.jpg

    ok so next we have to remove the 2 large screws holding down the red button shroud. once you remove this you will find the last small screw that needs to be removed
    I2gB4pZ.jpg

    screw 3, this is also a good time to locate the orientation of the selector switch. white dot was lined up with the N on the flash shroud
    b5hRVoT.jpg

    Now the flash socket should be completely free from the aluminum tube. you can simply push it out by removing the black end cap, and shoving a dowel, ruler or some object longer then the flash

    The tung is clipped in and you need to depress it in order to move the socket. I use a nail set to push the tung pin in, then use the dowel to push the whole assembly out the top. watch your eyes! the tung springs out!
    AR9unbu.jpg

    ok, so you notice the top part of the socket comes out with the tung, hold that tung tight! she's a bouncer!
    xdRtCSO.jpg

    continue to push until the second part comes out! be careful not to lose this locking block!
    8cW9Z5M.jpg

    with the flash now completely hollow we can mod the tung. we take the tung piece and bend it to a 90* angle like below. then take the tung and bend if over the metal ring that is kept inside the top part of the socket. so the tung should look like this

    qPnmX0H.jpg

    space it so the tung is centered in the top part of the socket. (see the socket in the top left of this picture)
    p7TDwVE.jpg

    your going to have to sand a notch into the groove the "ring" falls in. now with the tung wrapped around it its much thicker and wont fit in. 2 minutes with a small file and it will fit like a glove!
    AFMxK6d.jpg

    now with the tung centered we can re assemble the flash. so work in reverse, this can be tricky because the locking block will fall.. make sure the locking block is also installed like this. with the screw hole closer to the center
    EJL5KjP.jpg

    if you installed it correctly, the tung should be solid in there now. that ring, locks the tung in place.
    UHBZzuZ.jpg

    also gives it a real "star wars" feel with the bulb release below it.

    Next up, we have to remove the threads on the flash. this can be kinda tricky... if you have a chop saw with a metal blade its easy beans. as i did it that way in my youtube video. but if you don't have a chop saw, you can use a miter box, with a hack saw blade. take your time, and cut slow and it should come out straight.
    stanley-miter-boxes-20-600d-64_1000.jpg
    you can grab this miter box here at home depot
    Stanley Deluxe Miter Box with Saw-20-600D - The Home Depot

    IdUrLGi.png

    there is going to be some small burs on the end, lightly hit the edge ( NOT THE FLASH FINISH) but just the edge with some sand paper to remove the burs. this will make the End Cap, Trent supplies with the kit fall right in!
    mHLjbXc.jpg

    91F41A07-3F28-444A-B3EC-37EA5536EBE8.jpeg
    thank you for your time!
     
    Last edited: Feb 18, 2019
  3. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    please reserve this post 2
     
  4. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    please reserve this post 3
     
  5. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    please reserve this post 4
     
  6. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    Please reserve this post 5
     
  7. OdiWan72

    OdiWan72 Master Member RPF PREMIUM MEMBER

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    WOHOOO...I already love this thread.

    thanks so much gentlemen :)
     
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  8. nailuj

    nailuj Well-Known Member RPF PREMIUM MEMBER

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    This is great. Roll on posts 2 to 5. Love the way you are doing this in stages. You got me hooked.
     
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  9. Sundowner

    Sundowner Master Member RPF PREMIUM MEMBER

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    I’ve been waiting for this!!
     
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  10. teecrooz

    teecrooz Master Member RPF PREMIUM MEMBER

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    I have my TrooperTrent kit 2 arriving today and am all caught up other than cutting the threads off!
     
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  11. TheUnchosenOne

    TheUnchosenOne Member

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    It's no Graflex, but as it's own thing, I actually really like the Holiday Special lightsaber
     
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  12. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    Chris how are you going to go about cutting the thread off?
     
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  13. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    It’s the ugly duckling, you just have to love it
     
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  14. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    Gonna try and have this banged out this week. Double checking some things with Trent tonight and then working on this again tomorrow
     
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  15. TheUnchosenOne

    TheUnchosenOne Member

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    It's kind of what I'd have expected Luke's Jedi lightsaber to look like, in another world: thrown together by a guy with some blueprints and a little technical know-how but no actual guidance whatsoever
     
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  16. teecrooz

    teecrooz Master Member RPF PREMIUM MEMBER

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    Either hacksaw or dremel cutting wheel and a bit of sanding and filing.
     
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  17. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    Excellent!
     
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  18. Sundowner

    Sundowner Master Member RPF PREMIUM MEMBER

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    Im sure it was addressed but was the lettering taken off or are the reference pictures too low res?
     
  19. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    They must have removed the lettering on the graflite

    IF they used graflite, the t track and box covers the graflex logo pretty good

    Can’t really say which version they used, but for use either works for us
     
  20. Sundowner

    Sundowner Master Member RPF PREMIUM MEMBER

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    The same for the tiny lettering in between the ports on both versions?
     
  21. ALLEY

    ALLEY Sr Member RPF PREMIUM MEMBER

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    Strangely enough, my Graflite has neither “Graflex” nor “Graflite” branding on it, other than on the end cap. Apparently these versions are out there?

    A634E771-69A3-403C-961B-22233C33A108.jpeg
    80FC56E0-9EDE-4088-AC00-5B468E25DDF0.jpeg
     
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  22. Sundowner

    Sundowner Master Member RPF PREMIUM MEMBER

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    I was getting ready to say “ya I had one like that” but then I realized you bought it. Duh!
     
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  23. Trooper_trent

    Trooper_trent Master Member RPF PREMIUM MEMBER

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    Yeah the more attention these things (unnecessarily) get LOL the more we learn. It does appear there are several variants and there's not enough reference at this point to know for sure.
    The "GRAFLITE" versions at least appear to have painted letters that can be removed. The initial thought was that it was a GRAFLEX because you couldn't see GRAFLITE across the middle and the graflex logo is further down and covered by the tracks. But it very well could have been a GRAFLITE version with painted letters that were stripped off. And now there's this other variant that doesn't say anything. HAHA.
    The text around the ports seem to have all been removed so I'm definitely leaning more towards a non-Graflex variant. It's all so confusing and it's all for a prop nobody cares about! lol
     
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  24. teecrooz

    teecrooz Master Member RPF PREMIUM MEMBER

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    Some timely progress thanks to watching the video and mail being early today. Thanks halliwax and Trooper_trent!

    Still a little sanding left to do to get rid of the threading lip that is ever so slightly present due to using the hacksaw and not wanting to get too close to the tube itself.

    *edit
    Actually guys, the threading is an insert! Might be a way to pull it out if you loosen whatever adhesive there is. Only downside of accomplishing that would be that the bottom cap from the kit wouldn’t fit anymore. Stick with the cutting. It was quick and easy.
     

    Attached Files:

    Last edited: Feb 19, 2019
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  25. Trooper_trent

    Trooper_trent Master Member RPF PREMIUM MEMBER

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    Weird!
    Mine is definitely NOT an insert. Yet another variation!
     
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  26. Sundowner

    Sundowner Master Member RPF PREMIUM MEMBER

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    Mine is not an insert either
     
  27. teecrooz

    teecrooz Master Member RPF PREMIUM MEMBER

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    It didn’t look like one until after I cut it. Then I could see the seem. Open it up and see if there is a thick lip that then leads to the cardboard tube. Both of my Graflex versions with the end cap with holes are like this.
     

    Attached Files:

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  28. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    You know I ran across this problem when making the video and left it out.. I put acetone on the letters and it didn’t phase them at all

    I strongly believe they used graflites

    You can’t see any remnants of lettering

    At first I was sold for them being graflex’s but not being able to remove the black letters now has me thinking the black is anodized on...
     
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  29. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    Are the letters on the graflite recessed in? Like stamped in?
     
  30. jorged123

    jorged123 Member

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    Did you try hexane, methylene chloride, or another stronger organic solvent? I've used those too dissolve some tough paint before.
     
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  31. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    Never heard of them? Can you get that at Lowe’s/Home Depot?

    I was gonna try some paint stripper.. or using some oven clean

    Just didn’t have enough time
     
  32. jorged123

    jorged123 Member

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    Paint stripper many times has methylene chloride as one or all of it's makeup! So I'd say probably.
     
  33. Sundowner

    Sundowner Master Member RPF PREMIUM MEMBER

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    I don’t believe the letters are stamped but I could be wrong

    Edit

    After seeing yours, mine definitely isn't stamped. Mine also "catalog No. 2773" but is missing the writing just above the red button assembly.
    2547DEC7-EB3D-475E-845F-F4B76FBEF4E7.jpeg
     
    Last edited: Feb 19, 2019
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  34. jorged123

    jorged123 Member

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    Be sure to have great ventilation! methylene chloride in a confined space has been known to be deadly!
     
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  35. thd9791

    thd9791 Master Member RPF PREMIUM MEMBER

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    Lucky lightsaber

    Anyway - I have the stamped GRAFLITE version with no words above the red button - and yes, now that I look at it, the threading is a separate piece! I wonder if the endcap cut-off theory works better with this threaded sleeve removed...
     
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  36. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    Thank you very much!!
     
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  37. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    Wait a minute I’m confused... your graflite has a threaded end that can come out?!


    So it sounds like there’s graflites with stamped wording and with out... *...
     
  38. thd9791

    thd9791 Master Member RPF PREMIUM MEMBER

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    Let me work on it and get a picture up on here
     
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  39. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    lol you know me all too well... visual learner

    Bless you Tom
     
  40. thd9791

    thd9791 Master Member RPF PREMIUM MEMBER

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    I didn't see a measurement up there, what length do you trim down to with a saw?
     
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  41. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    I just cut the threads off. That’s it
     
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  42. thd9791

    thd9791 Master Member RPF PREMIUM MEMBER

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    So, my threads ripped off with pliers. Nor sure what to do now, but it's definitely press fit inside 20190219_171938.jpg
     
  43. steven giunta

    steven giunta Well-Known Member RPF PREMIUM MEMBER

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    Nothing on the graphlite is stamped in. I used some paint thinner and mine now is completely blank.
     
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  44. Sundowner

    Sundowner Master Member RPF PREMIUM MEMBER

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    1262.gif
     
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  45. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    Steve judging by my reference there looks like there are a few graflite variants

    The variant with out stamped letters looks like the no. 2773 is missing around the top edge, seen on other graflites

    Other graflites seem to have the stamp letters

    This is what I’m going with, with the research I’m going today

    I’m also curious on Toms graflite but I can’t get his picture to load on this * ghetto WiFi I’m on right now...
     
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  46. halliwax

    halliwax Legendary Member RPF PREMIUM MEMBER

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    Dang Tom... I wonder if my thread would come right out like that too.... too late for me now since I cut it

    It would save a lot of people time and effort if all the thread just pulled right out
     
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  47. thd9791

    thd9791 Master Member RPF PREMIUM MEMBER

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    Yea, its a sleeve slid inside the bottom of the flash, its weak but really tightly fit in there. im tempted to stick a dremel or saw in there and break it apart
     
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  48. Trooper_trent

    Trooper_trent Master Member RPF PREMIUM MEMBER

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    Like mentioned before, my end caps were modeled to fit cutting the threads off so if someone has my end cap and then pulls the threads out, it's not going to fit.
     
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  49. steven giunta

    steven giunta Well-Known Member RPF PREMIUM MEMBER

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    You are right,mine didn’t have the 2773 on the top.i thought there were only the two variants,graflex and graflite,
    But I guess there’s more then just the two. glad I got lucky and got the right one. can the stamped on writing be sanded off ?
     
  50. thd9791

    thd9791 Master Member RPF PREMIUM MEMBER

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    This is important, the insert seems to be the same thickness (or a tad more) than the wall. Keep the sleeve in there to use trooper trents kit.
     
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