Sanding down blades to fit Luke FX

[Master Nero Attoru]

Hey everybody, I'm sure at least some of you know about my custom Luke ROTJ, originally a converted FX I bought off eBay which was souped up by Ultra with awesome features.  I currently have one blade that fits this hilt, the one that originally came with it, but I was wondering if you had any advice on how to sand down a blade to fit the emitter.  Basically my regular Ultrasabers blades are a hair too wide and won't fit, and when you check the pages for blades on the US site it even says that they need to be sanded down to fit converted FX sabers.

Any tips on how to go about this (tools, techniques, etc) would be greatly appreciated.

[Hebi]

Well, I know that if you ask in your order comments, US can sand them for you... Although, I'm pretty sure...

Hebi

[Master Nero Attoru]

Well, I know that if you ask in your order comments, US can sand them for you... Although, I'm pretty sure...

Hebi

Thanks for the reply - I'm pretty sure you're right about that.  If I decide to get a new blade I'll be sure to do that, although I was mostly looking for advice on how to sand down the blades myself.  I seem to have quite the collection of blades and I'm sure I could find the right tools to do it if I knew how.

[ThreadJack]

You have a piece of sandpaper and a hand?

[Master Nero Attoru]

You have a piece of sandpaper and a hand?

Yes to the first.  The second... let's just say I had a lightsaber training accident or two.  I could try with my feet though!

No but seriously, can I just use sandpaper?  It sounds so obvious but I didn't wanna mess up my blades, I typically have only used it on wood and whatnot and didn't know the effect it would have on polypropylene.

[ThreadJack]

It'll scratch it up(if it's a UE blade you won't even be able to tell), but it shouldn't do anything other than that.

[Ultra]

Measure socket depth
Put strip of masking tape on blade above where blade should disappear into socket
Stuff a wad of paper towel inside bottom of blade to prevent dust from entering blade
Sand portion of blade between masking tape and bottom of blade tube with ~300 grit sandpaper by holding the blade against the paper and spinning the blade.
Test fit blade from time to time
Stop sanding when blade fits
Remove paper towel plug
Remove masking tape
Put blade in socket
Tighten blade retention bolt
Get on forums and share results
Buy Ultra chicken wings

[Master Nero Attoru]

Measure socket depth
Put strip of masking tape on blade above where blade should disappear into socket
Stuff a wad of paper towel inside bottom of blade to prevent dust from entering blade
Sand portion of blade between masking tape and bottom of blade tube with ~300 grit sandpaper by holding the blade against the paper and spinning the blade.
Test fit blade from time to time
Stop sanding when blade fits
Remove paper towel plug
Remove masking tape
Put blade in socket
Tighten blade retention bolt
Get on forums and share results
Buy Ultra chicken wings

You're the man Ultra.  As soon as I make it to one of these cons you guys go to I will be sure to bring a big plate of chicken wings for you

[Master Artorius Vidnyl]

Buy Ultra chicken wings

Ok Nero and I will definitely be doing this before months end.  What kind of chicken wings you like?  Bone in or out?  Any specific type of sauce or seasoning?

[ThreadJack]

Yummm, Chicken wings....

Sorry what were we talking about? That's right sanding down blades. Ultra just explained it very well. I actually didn't think it was that involved, I would have just started sanding! XD.

[Danakar Endeel]

Oh noes! I'm a vegetarian! 

Tofu-wings for me then

[Caine]

One thing NOT to do is use a dremel. It may seem like a good idea at first, but it may end up uneven. And if the blade is thinner on one side then the other, than it is possible for the blade to crack.

Just another thing to think about. 

[Master Nero Attoru]

One thing NOT to do is use a dremel. It may seem like a good idea at first, but it may end up uneven. And if the blade is thinner on one side then the other, than it is possible for the blade to crack.

Just another thing to think about. 

Thanks Caine!  That is one thing I considered, and the whole "screwing the blade up" is the reason I asked here first.  I'll avoid that for sure.

[Ultra]

Ok Nero and I will definitely be doing this before months end.  What kind of chicken wings you like?  Bone in or out?  Any specific type of sauce or seasoning?

Wingstop regular wings, original hot.