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  1. RPF Premium Member roygilsing's Avatar
    Member Since
    Mar 2014
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    Rotterdam, the Netherlands
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    878
    Nov 4, 2014, 11:39 AM - Various OT lightsaber parts (TFA clamp covers and bottoms now available) #1

    **** UPDATE FEB 2016: TFA edge connector clamp cards available ****
    **** UPDATE JUNE 2016: TFA clamp covers and bottom plates available ****

    Hi all, let's start with some of my art work:
    Click image for larger version. 

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    Not so long ago, not even a year, my obsession with lightsabers started with Obi-Wan's lightsaber from ANH. Since then I was hooked. Because I'm into CAD modeling as a design engineer, I wanted to build the most accurate 3D model of the OB1. I posted some computer renderings of the result on this forum back then, like the ones above. I was pleased with the result and when I had the chance I ordered the weathered OB1 replica from Roman's Empire which was truly amazing!

    I quickly learned more about the other saber hilts from the original trilogy (Graflex!) and started to collect parts for my own builds. As a product developer I wanted to use my skills and add something to the replica prop building community and instead of buying the parts I needed, I developed my own. (I'm also very stubborn!). I made very accurate CAD models of all the parts, by measuring real parts and by reverse engineering from pictures of original props, and then used various fabrication techniques for the production.

    The parts I made so far:

    • T-track profile; for the Graflex & MPP saber grips and E-11 stormtrooper blaster
    • D-ring with clip; from Luke's ANH saber
    • Exactra Bubble strip; used in many sabers
    • Kobold clip (from the droid caller) used on Luke's ESB with a D-ring
    • Belt Clip from Luke in ANH, ESB and ROTJ (maybe also good for other costumes)
    • PCB Edge connector; clamped in the Graflex of Luke's ESB

    I met RPF-member Sym-Cha and he helped me enormously with so many details and he kept on bringing ideas for more parts I still have many to add to the list later!

    I will try to give some background info on how each part came along:

    T-track
    The references for the dimensions of the cross-section are archive pictures of the Vader MPP and Luke ESB and by using 3D CAD software for perspective matching and measuring. So I didn't take measurements from other replicas but based it purely on my own research.
    Here is an screen grab of the perspective matching in 3D:
    Click image for larger version. 

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    I invested in the tooling cost and in the production (extrusion); first in rubber (elastomer) but later in the screen accurate hard plastic (PVC). I now have plenty of profile for the rest of my life!!
    Click image for larger version. 

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    The result is a beautiful and in my opinion a very screen accurate T-profile. I can cut it to any length. Here is a comparison pic (made by Sym-Cha):
    Click image for larger version. 

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    D-ring with clip (or strap)
    Very little is known about the shape of the D-ring and clip. They are therefore discussed intensely in other posts (here and here). Here you see a screen-grab in 3D to determine the correct size and shape in perspective as an overlay on the famous toe pic:
    Click image for larger version. 

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    It took me MANY weeks to search for the correct D-ring, which I finally found in a small local shop. It is a 1” (25mm) ring, with an inner diameter of 0.9” (23mm), outer diam. 1 1/8” (28.5mm). The shape is very round (more than half a circle shape).
    I then made a production run on the stainless steel clips based on Sym-Cha’s template, which proved accurate and which is considered to be pretty cool looking by many RPF members. You can attach the D-ring to the back of a Graflex with a vintage English rivet. Mine looks like this:
    Click image for larger version. 

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    Exactra bubble-strip
    The bubble-strip was based on real calculator bubble-strips from the Exactra 19 and 20. I first made a CNC machined version in PMMA which was extremely close to the original:
    Click image for larger version. 

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    The top one is the original Exactra 20 bubble-strip and the lower one is my CNC version.

    It was ‘uncut’ and could easily replace an original (don’t worry for fraud: I only made one and in case I will ever sell some, I will mark them as a replica). It is a bit pricey though to make in large quantities. Instead I did a run in casted resin. This one was based on the Exactra 19 and already pre-cut to fit a Graflex clamp. The result is very nice and accurate:
    Click image for larger version. 

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    The bottom one is the resin casted version.

    Maybe, later, I could perhaps start a production run in polycarbonate on a real injection molding tool. This is how the real strips were made, but the investment is high and the return on it is risky. I might have to sell hundreds to make it worthwhile. Let me know what you people think!

    Kobold clip
    UPDATE (dec-11): The Kobold Clip replicas are now ready and look stunning!
    They are CNC machined from brass and have a nickel plated finish.


    Belt clip
    The metal belt clip (to carry your lightsaber around on conventions or in your house) was based on these pictures:
    Click image for larger version. 

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    I thought it would be cool to produce a whole bunch of them (they were produced together with the D-ring clips). You can attach it to your Jedi belt with 2 rivets. In case you wonder: the belt should be 1 7/8” (=47mm) wide. This is my belt clip in stainless steel:
    Click image for larger version. 

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    PCB Edge connector
    The part clamped in Luke ESB lightsaber is a piece of a vintage computer’s edge connector. They say it's from an old HP multibus boards, like this one (I found this on the internet, it said Hybricon WW2):
    Click image for larger version. 

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    I based my replica on this picture from the archive where the exact shape and size can be seen:
    Click image for larger version. 

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    The 13 connector strips are rectangular shaped with a narrow bit on the right side. The PCB material is not commonly used anymore, but I have a good friend who managed to find the correct color and he produced the correct connectors for me. Here is the result:
    Click image for larger version. 

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    That’s it! Thanks for your attention. Please let me know if I made any mistakes or if you think I can improve the parts. Let me know what you think and have a look on my website.

    Roy
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Last edited by roygilsing; Jun 21, 2016 at 4:03 AM. Reason: update new item
  2. RPF Premium Member NeoRutty's Avatar
    Member Since
    Feb 2013
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    Vancouver, BC. Canada
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    3,889
    Nov 4, 2014, 12:24 PM - Re: Various custom build lightsaber parts (original trilogy) #2

    Nice... I will definitely be picking up some Kobold clips and t-track.

    Might I HIGHLY suggest a MOM ROTJ Vader?!?!?!!

    I've been looking for this shroud FOREVER... a guy named Kenny did it in the past, but no one since.

    Chaim has parts for reference... lots of online ref... you could even have the thread showing on the control box button that Kenny left off...
  3. RPF Premium Member roygilsing's Avatar
    Member Since
    Mar 2014
    From
    Rotterdam, the Netherlands
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    878
    Nov 4, 2014, 1:10 PM - Re: Various custom build lightsaber parts (original trilogy) #3

    Hi NeoRutty,
    I will be looking into the shroud later indeed. Chaim and ParfaiteLumiere already started about it
  4. Sym-Cha's Avatar
    Member Since
    Jun 2008
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    Groningen, Netherlands
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    5,779
    Nov 4, 2014, 2:46 PM - Re: Various custom build lightsaber parts (original trilogy) #4

    Excellent show of craftsmanship ... and I'm glad the custom Luke ANH D-ring is in production yet again, though I never claimed it to be screen-accurate, it received some great comments and followers

    The saber parts mentioned by NeoRutty is Vader's stunt from ROTJ and based on a real G R A F L E X ... seen here on the bottom



    Chaim
  5. RPF Premium Member BobasBounty's Avatar
    Member Since
    Jun 2002
    From
    Charlottesville, VA
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    157
    Nov 4, 2014, 10:48 PM - Re: Various custom build lightsaber parts (original trilogy) #5

    Sent you a PM about some T-track.

    Andy
  6. RPF Premium Member thd9791's Avatar
    Member Since
    Jul 2011
    From
    Buffalo, New York, United States
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    4,258
    Nov 5, 2014, 1:29 AM - Re: Various custom build lightsaber parts (original trilogy) #6

    I REALLY like your stuff. Glad and surprised you have the resources to do this. expect a few orders from me.
  7. Luke the Belter's Avatar
    Member Since
    Feb 2014
    From
    Düsseldorf - Germany
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    434
    Nov 5, 2014, 6:29 AM - Re: Various custom build lightsaber parts (original trilogy) #7

    Well done Sir.

    I think it was good to get Chaim on your boat
    The pieces look fantastic AND you beat the price tags you can normaly find on the internet.
    Can't say what I've payed to get a Parks Kobold Clip and now you say approx. 15 $...oh my...

    That's so great.
  8. Mystery Chunk RPF Premium Member PoopaPapaPalps's Avatar
    Member Since
    Oct 2010
    From
    IA, USA
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    2,854
    Nov 5, 2014, 6:42 PM - Re: Various custom build lightsaber parts (original trilogy) #8

    Order placed, my man! Can't tell you how excited I am for this!
  9. Jedi Reali's Avatar
    Member Since
    Feb 2000
    From
    Philadelphia, PA, USA
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    426
    Nov 6, 2014, 1:20 AM - Re: Various custom build lightsaber parts (original trilogy) #9

    Great stuff, thanks for this!

    Might I suggest altering the thread title though... I literally ignored this thread multiple times because I thought it was about OT style parts to build custom lightsabers with, which would not interest me. (Saying "custom build lightsaber" makes me think of a lightsaber that is not in the movies or the EU.) I finally clicked on it out of boredom and here it was a thread I've been waiting for. If it simply said "OT Lightsaber Parts" I would've known immediately what it was about.
  10. RPF Premium Member roygilsing's Avatar
    Member Since
    Mar 2014
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    Rotterdam, the Netherlands
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    878
    Nov 6, 2014, 2:21 AM - Re: Various custom build lightsaber parts (original trilogy) #10

    Great suggestion Jedi Reali, but I can't change the title of the thread it seems.
    Learning something each day
  11. RPF Premium Member NeoRutty's Avatar
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    Feb 2013
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    Vancouver, BC. Canada
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    Nov 6, 2014, 3:03 AM - Re: Various custom build lightsaber parts (original trilogy) #11

    If you hit "edit" there will be a second "edit" button that will let you change the title.
  12. jkno's Avatar
    Member Since
    Jun 2008
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    Dracula's Castle
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    Nov 6, 2014, 8:09 AM - Re: Various custom build lightsaber parts (original trilogy) #12

    The T-track looks really cool!
  13. Sym-Cha's Avatar
    Member Since
    Jun 2008
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    Groningen, Netherlands
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    5,779
    Nov 6, 2014, 8:17 AM - Re: Various custom build lightsaber parts (original trilogy) #13

    NeoRutty said: View Post
    If you hit "edit" there will be a second "edit" button that will let you change the title.
    I tried your suggestion with my original D-ring thread to no avail ... it only changed the title of that particular post ... not the main thread title

    Chaim
  14. Luke the Belter's Avatar
    Member Since
    Feb 2014
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    Düsseldorf - Germany
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    Nov 6, 2014, 8:34 AM - Re: Various custom build lightsaber parts (original trilogy) #14

    Sym-Cha said: View Post
    I tried your suggestion with my original D-ring thread to no avail ... it only changed the title of that particular post ... not the main thread title

    Chaim
    Try this:
    Klick "Edit" and then "MoreReplyOptions"

    It worked for me
  15. RPF Premium Member parfaitelumiere's Avatar
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    Dec 2010
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    1,062
    Nov 6, 2014, 8:55 AM - Re: Various custom build lightsaber parts (original trilogy) #15

    You will receive the Koboold reflector holder soon.
    I left the spring small bolt and balls it will be easier to measure the bolt.
    please take care about the bolt hole place, I sent you a file with correct place for centering the bold holes.
  16. RPF Premium Member roygilsing's Avatar
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    Mar 2014
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    Rotterdam, the Netherlands
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    878
    Nov 6, 2014, 9:31 AM - Re: Various OT lightsaber parts #16

    Great! I did manage to change the title! Thanks NeoRutty and Jedi Reali; that second edit did the trick.

    Roy
  17. Curmudgeon's Avatar
    Member Since
    Aug 2013
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    Nov 6, 2014, 11:04 AM - Re: Various OT lightsaber parts #17

    Awesome! I'll definitely be placing an order for the ESB kits when they're finished!
  18. Sym-Cha's Avatar
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    Nov 6, 2014, 11:59 AM - Re: Various custom build lightsaber parts (original trilogy) #18

    Luke the Belter said: View Post
    Try this:
    Klick "Edit" and then "MoreReplyOptions"

    It worked for me
    I already did ... must be an apple issue or something ... quite annoying indeed ... the same as trying to make a members name into a direct link in a post with an underscore line ... humbug! ... let's just move along and enjoy these newly replicated lightsaber parts ... shall we here's a straight sideshot :



    Chaim
  19. Lutso's Avatar
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    Orange County
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    Nov 6, 2014, 12:36 PM - Re: Various OT lightsaber parts #19

    You are one cool dude.
  20. Member Since
    Oct 2014
    Messages
    4
    Nov 6, 2014, 2:54 PM - Re: Various OT lightsaber parts #20

    Excited that your store is now live! Will be placing an order soon - thank you for such detailed photos here!
  21. RPF Premium Member kurtyboy's Avatar
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    UK
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    Nov 6, 2014, 3:22 PM - Re: Various OT lightsaber parts #21

    I am already a fan of your work!
  22. RPF Premium Member Darth Lars's Avatar
    Member Since
    Jun 2002
    From
    Stockholm, Sweden
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    Nov 6, 2014, 10:50 PM - Re: Various OT lightsaber parts #22

    Real nice-looking T-track. I've always found Gino's T-track to be too thin.
  23. RPF Premium Member thd9791's Avatar
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    Jul 2011
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    Buffalo, New York, United States
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    Nov 7, 2014, 12:26 AM - Re: Various OT lightsaber parts #23

    I just noticed this this afternoon. I Like the clean sharp look though. Regardless, I happen to find Roy's to be...a little more accurate. This is me looking at MOM and Archive photos with a gut reaction. Anyways, Roy are these extruded too?
  24. RPF Premium Member roygilsing's Avatar
    Member Since
    Mar 2014
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    Rotterdam, the Netherlands
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    Nov 7, 2014, 2:21 AM - Re: Various OT lightsaber parts #24

    Hi thd9791, yes the profile is extruded and measures 13.5 x 7.1 mm with less than 0.1 tolerance.


    Roy
  25. RPF Premium Member GINO's Avatar
    Member Since
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    bright center of the universe
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    Nov 7, 2014, 11:15 AM - Re: Various OT lightsaber parts #25

    Darth Lars said: View Post
    Real nice-looking T-track. I've always found Gino's T-track to be too thin.
    Ok since I was dragged into this and my stuff is being included in comparisons, I feel this needs to be said.

    I think it's great that there are t-track alternatives especially cheaper ones.
    And roygilsing I don't want this post to come off as putting down your stuff. But when comparisons come up that include my stuff or untrue statements are made such as the one quoted here I'm going to have to chime in and set the record straight.

    But as far as accuracy goes, mine is the only one in that comparison shot that has the actual true screen-accurate profile.
    My track was created from measurements taken from actual screen-used t-track as opposed to using screen shots etc for the basis of the replica.
    I think the comp photo shows the differences quite clearly.

    I think this new stuff is pretty close, definitely closer than marv's or blastech, but to say it is perfectly screen accurate would be a generalization.



    .

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