Saber Forum

Does anybody know how to fix this and/or knows how the guarded switch is held in place?

As you can hopefully see, the button is stuck in the downward position and won't come up again. I think it's a little bit diagonal as well and it's to far down to really get a hold on it. And I noticed that the rim/brim/edge of the guarded switch seems to have came up out of the hilt. And yes it misses a piece, but it's my favourite training saber, that's why it dropped today (again) and now I have this issue....

Yes I can send it back to US, but the shipping costs alone are more than the price of a new saber (thanks to living on the other side of the globe and taxes...), so I'm hoping I can fix this myself.

(https://i.imgur.com/cZyiEns.jpg)

(https://i.imgur.com/cQUp5ld.jpg)

(https://i.imgur.com/ncsXi1k.jpg)

(https://i.imgur.com/1V7Ng1i.jpg)

You could try to replace it with a new switch. There's almost no other way to fix that.

 If you turn the saber so that the switch faces downwards, does the middle part slide out again? That could indicate a problem with the spring inside the switch. Or doesn't it move at all?

No, the button isn't moving at all, it's all stuck.
And yes, I'm a bit worried that I have to order a new switch...

It'll have to be replaced and UltraSabers just hot glues the switch to the hilt so use a heat gun or a hair dryer and run it around to heat up and melt the glue. Be careful since that plastic ring tends to melt or shrink under long periods of heat treatments.

I've broken countless guarded switch and I just replace them with latching AVs

Thanks Infinite, that's advice I can work with!
No offence intended Racona Nova, again thank you as well!

I'll give the heatgun a try tomorrow. Now I only hope I can repair the switch otherwise I'll need to order them.  :(

It's okay ;) Nothing to worry about!

You don't need a heat gun for that switch. Only the AV switches are glued in. The plastic guarded switches are press fit into a tight hole making them even easier to replace. You can pry it out carefully but that will mar the saber around the hole. I prefer to pull them out using a pair of thin/needle nosed pliers to grip the intact edges of the guard ring. Either pulling opposite edges alternately or trying to twist it while pulling usually helps. Then just attach the wires to the  new one and press it in there.

I have done many and I  order many new sabers I get with the guarded switch specifically so I can pull it out and tap the hole to thread in a 12mm AV switch. Like this one in my Monarch:

(https://i.ibb.co/CnhxPGx/15789387999106470409404684163626.jpg) (https://ibb.co/9qsRZ5R)

Thank you Firehand.
Just so I understand correctly. If I find someone who can tap, or get the tools myself (and learn how to tap). The whole of the guarded switch can be tapped for a 12mm diameter screw/new switch? Do I need to know a threat size as well?

I'm still hoping I can fix the current switch and won't have to order a new one. And it'll probably be the same one, but still this I really like the idea for a future project. Or this one if I decide otherwise.

BTW, Points to all! Thank you much appreciated!

Yes it can be tapped to fit 12mm AV switches.  You need to know the thread pitch of the switch you choose to install. To do it you have to attach the wires first then turn the switch in while managing the wires inside. It is not an easy thing and takes a good amount of patience but I like the look and like doing it to mine.

My first repair attempt came to an early stop. The guard of the guarded switch turned out to have been broken of. The lower part was still nicely stucked inside, so I just pulled it up a bit to get a nice press fit. It's not my definate repair, I'll have to order one or more switches, but hopefully it will do for now.

Made a few pictures along the way:

(https://i.imgur.com/34Xm3wD.jpg)

(https://i.imgur.com/0Cz1CXJ.jpg?1)

(https://i.imgur.com/Fsl2Vab.jpg)

(https://i.imgur.com/hduEDVe.jpg)

(https://i.imgur.com/IGFo9c1.jpg)

Where are you. If in the US i could send you a switch. I have some i pulled out just to make the aesthetic change i like.

Thank you for the offer, but I live on the other side of the ocean, the Netherlands. (small European country, mostly famous because of their capital city Amsterdam  ;) )

Oh. Don't know about shipping there. Hope you find one easily.

I have the same issue on my Aeon V4.

Its a very common problem when dueling or dropping sabers. Luckily its also so easy to fix.

The easiest way to get that switch out is to take a 10mm drill bit and SLOWLY drill through the center of the switch and afterwards pull out what remains of the switch. That is what we do. Go slowly and stop the drill right after the threads so you don't tangle the wires inside around the bit. Since the switch is plastic, it easily drills and you can you then replace it with any switch you would like that fits in the hole. Use a drill press.

Thank you for the reply! I will definately remember this.
I'll order a few switches upcoming months, but I have to save a bit of money first. Living in the Netherlands means that it's better to order in one bigger order instead of several little orders thanks to shipping costs and taxes.
But I'll keep everybody posted.

Again thank you, nice to know that the people of US also read and reply. Even though you all must be very busy due to the immens order amount last few months.

Thanks for the advice!

I'm very interested in doing just this as well (ie change out guarded to an AV).

A few questions.
1. What do you mean by "You need to know the thread pitch of the switch you choose to install?"

2. After getting the guarded out then the objective is to drill a 12mm hole for the new switch?

3. Will any 12mm AV switch work or are there different varients?

Thanks for helping!

 I'm very interested in doing just this as well (ie change out guarded to an AV).

A few questions.
1. What do you mean by "You need to know the thread pitch of the switch you choose to install?"

There are different switches and different manufactures and some have different threads. You need to know what size the threads and be sure to have the right/matching tap.

2. After getting the guarded out then the objective is to drill a 12mm hole for the new switch?

After pulling out the switch you have a hole remaining that is a little less than 12 mm and ready to cut threads into.

3. Will any 12mm AV switch work or are there different varients?

Yes to both. There are different variants around but if you plan the project and make sure to have the right tools and preparation any will work.

Ahh, got it. You may have mentioned it in an earlier post but I didn't realize I'd be drilling a threaded hole. All the AV switches I have see have a nut so I was thinking I'd have to somehow screw that on the bottom side (remove all the guts to give some room and finesse the nut on). This makes more sense now and sounds easier.

Thx!

You can use the nut on some but some of the switches are too short and Ultrasabers are a bit thick.