Build Thread for my take on the ROTJ Luke Lightsaber (fully machined)

TD-4242 · Apr 17, 2018

I have started making a ROTJ Luke Lightsaber, for a near future run.

This is 100% manually machined out of Aluminum brass and steel. I am doing full detailed build videos so you can see how they were made.

Primary goals:
1. Complete video log of the entire process
2. Accuiracy
3. Durability and everything being positively affixed (ie no glue)
4. Additional features like room for electronics

Full Playlist:
https://www.youtube.com/playlist?lis...hPi3IHoex9p5zb

Latest Video:

TD-4242 · Apr 17, 2018

Hijacking this post to show the full machining video series of making all the parts.

Just the tip and for about 40 minutes

making the emitter

the brass part

cutting and cleaning all thread to hold it all together

the last coupler

Here are some images of the first prototype being machined and completed.

This one was done as a single 12" piece of aluminum. This was difficult to machine due to the plunge cuts and the fact that any mistake ruined the entire piece. In the end it was still pretty nice.

Halliwax · Apr 17, 2018

This is nuts!! I always wondered how the pommel cubes are cut

Any chance could you make me a short video of how you actually cut the cubes?

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TD-4242 · Apr 17, 2018

Ask and you shall receive:

The index head in the mill is normally used for cutting gears, it has been an experiment for me as I am not an experienced machinist. This project as a whole has been a self training exercise.

If you are interested in the "training" materials I have been using to learn the use of my new tools look up these youtubers:

Abom79 - talented professional machinist that has hundreds of great videos of work he has done
MrPete222 - high school shop teacher to something like 30 years, plus time working as a machinist for Catipilar.
Ave - if you need inspiration to fuel curiosity or just great dick jokes.

TD-4242 · Apr 17, 2018

Some pictures of second prototype with individual components.

Halliwax · Apr 17, 2018

TD-4242 said:
Yes of course, I was actually planning to do a full machining video of making all the parts.

The index head in the mill is normally used for cutting gears, it has been an experiment for me as I am not an experienced machinist. This project as a whole has been a self training exercise.

If you are interested in the "training" materials I have been using to learn the use of my new tools look up these youtubers:

Abom79 - talented professional machinist that has hundreds of great videos of work he has done
MrPete222 - high school shop teacher to something like 30 years, plus time working as a machinist for Catipilar.
Ave - if you need inspiration to fuel curiosity or just great dick jokes.

Thank you I’m going to look them up!

I for one would LOVE a video log, that would be awesome!!

That prototype came out great for the first try!!

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TD-4242 · Apr 17, 2018

A little out of order, but here is the First prototype I did out of a solid piece of aluminum. The in progress pics of it were in the first post, these are the finished version.

RickyD9 · Apr 17, 2018

Spot on mate. Looks stunning

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TD-4242 · Apr 18, 2018

Well this actually turned out better than I thought it would. Going to put together another drawing of it so I can start making more.

Halliwax · Apr 18, 2018

Love that control box!

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TD-4242 · Apr 18, 2018

I still need to hollow it out. I'll also machine a flat on the saber where it mounts,then drill and tap holes to screw it to the main saber. I may also machine a hole into the actual saber hilt for wiring access if someone desired to utilize it.

TD-4242 · Apr 18, 2018

Ok, did the steps in the previous post

Halliwax · Apr 18, 2018

I love how you did the control box! Wicked idea!

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teecrooz · Apr 18, 2018

That turned out nice! What a fun project.

TD-4242 · Apr 18, 2018

Quick comparison pics. Not sure how I'm going to do the arrows...

Mechanized · Apr 18, 2018

That’s some impressive machining you’ve done there. Saber is looking fantastic :thumbsup

TD-4242 · Apr 19, 2018

Ok, got an idea for doing the triangles from this AvE video: https://www.youtube.com/watch?time_continue=761&v=v68KtZ_NBP4 Skip to the last 1/4 of the video to see the actual making of the triangular broach.

And using some of the triagular LEDs from here https://thesaberarmory.com/product-category/components/leds/

I also milled, lapped and filed a small chunk of steel for the button.

Edit/Update: for those interested in machining, I first found this video from AvE https://www.youtube.com/watch?v=d_LSPX8cNaE probably more 2 years ago. It started me into watching his vi-ja-ohs which eventually got me far more interested in the milling and lathe work and led me to watching MrPete222 and Abom79 videos.

TD-4242 · Apr 19, 2018

Ordered me a GoPro camera and will start making some mounts so I can mount it to the machines. Hope I can get better results than my phones camera.

TD-4242 · Apr 19, 2018

well, gave a quick proof of concept, ground down a small chunk of tool steel to a 5mm triangle shape and sharpened the end of it to attempt broaching. This I just did with a hammer holding it in hand like a nail. for the final part I'll create a jig to hold it in a press.

Halliwax · Apr 19, 2018

Dang cool idea!

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Build Thread for my take on the ROTJ Luke Lightsaber (fully machined)

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