checked closer to the episode,and took informations.
Already asked for a 2"x 15" blank,even I thin 12" could be enough.
Then,about lathe,there would be several ways.
one is quite complicated,but offers room for complete internal elements,and electrocnics.
-rounding the external shape,mandrel one side and tailstock on other side,or,simply,two tailstocks,one in the mandrel....
Once it is rounded,put it in the mandrel,and then drilling,I suppose would be made in two times,because 15" is a long piece of wood,same problem for diameter enlarging...would have to care about centering,and weakness of wood,especially in a mandrel,maybe will have to drill and give final diameter immediately,then put a partial metal core.
Once drilling and internal lathing is achieved,putting a solid part of metal inside,of course,longer than the wood,would probably bet the best way,because it will get stronger,and easier to use.
Then the wood is "locked" using a bolt,maybe at the future activation button place for example...
would be easy to give final shape,no wood compression or stress using a metal core,to minimise the cracks,especially with thin walled body...standart wood lathing toold,used by hand,"freeform"work,maybe create the "critical areas with metalworking tool with measurments,to know which is critical diameter...
Other is simplier,available with a classical wood machine and classical wood tools:
- beginning with external shape and creating 2 metal parts,but would need a plain lightsaber or would mean hand drilling,I think it's not a good idea,especially if electronics is prefered.
possible to begin with "pommel" drilling on lathe machine,then have a "small" tailstock that could go inside,but would need external metal shield to rotect the woold,and would mean hand finish.
