Vader ROTJ Saber Center Band

[cayman shen]

I'm thinking about making my center band soon, and I'm leaning toward cheap and dirty, which is probably exactly like the real thing.

I was going to try a sink tube, but I suspect the gap will be too wide. Then I though about wrapping a thin sheet of metal around the tube until it conforms to shape, but I thought that might not work real well.

I'd even consider one without a gap, since I'm doing a slightly idealized saber (even screws, still weathered. uneven emitter rod, I'm making some personal choices in terms of cherry-picking between accuracy and idealization). But who sells a small bit of tube with an ID of 1.5? I mean, the shipping on OnlineMetals is waaay too much for such a bitty piece.

THEN, once I get one, how does it hold the saber together? Is it just glued? Is there a dowel in the saber to stiffen it? Wouldn't that conflict with the screws? Lots of questions...

Thoughts?

CS

 

[Boba Frett]

I just use sink tubes, it doesn't meet all the way around anyway.

 

[cayman shen]

Does the sink tube leave you the right sized gap? I was concerned it might be too wide. Thought I'd check before blowing the money.

 

[Darth Detroit]

Nope, sink tube does the trick perfectly

 

[cayman shen]

Cool, thanks. Now for a profoundly stupid question...any tips on splitting it down the center? If I dremel, it won't be straight, so I'll have to file and lose material (I really want to minimize the gap). Maybe if I put it on a square and score it over and over with a utility knife? I mean, the brass in sink tubes is SUPER flimsy.

I can't think that I'd hacksaw it straight, but maybe because it's so soft...is that the usual solution? (God this question makes me feel DEEPLY incompetent...)

 

[cayman shen]

Oh yeah, and what is it, 2" wide?

 

[Smiling Demon]

Just use tin snips. They are like scissors for metal flashing and just cut a straight line and dress up the edges.

Kenny

 

[cayman shen]

Oh yeah. Duh.

 

[Darth Detroit]

Tin snips, make sure they are the ones that cut straight. I hae used a Dremel wheel before and didnt have a problem. i drew theline first, then cut away. Only bad thing about tin snips is, if your not careful they will make the tube edge roll up. You just have to bend it back into shape.

 

[Boba Frett]

I have used a Dremel before, and even a hacksaw blade.

 

[cayman shen]

I guess if I buy a whole length of tube, I'll have enough to screw up a few times. I can't cut straight with a dremel. Just can't do it.

 

[SaberFreak]

Ship the sink tube to me, and I'll cut it for you and pay for return shipping. All I'm asking is to keep a length enough for my own centre band

(I can't get brass tube here in that ID and that thin )

 

[obi1kenny]

Yup, all good info and tips here. Just use the old sink pipe and slit it down the middle with one of the tips already mentioned.

2 inches long is about right.

And yes, you will want to put something in the center of the 2 half, like maybe a piece of wood dowel if you can find one big enough. Or you could also split another sink tube in half and fold that up to fit inside as well.

Back when I was offering kit parts I offered a machined piece of aluminum tubbing that was tapped out to accept screws to secure each end of the graflex tube and those were hidden under the control box.

 

[cayman shen]

Ken, I got your PM, thanks. My high school has a machine shop, so maybe I can sweet talk the teacher into making a nice even slit for me...