How would I make a stunt chassis out of PVC pipe?

[Witchpig]

Does anyone here know of any good tutorials or resources for how one would go about creating a chassis for the battery box for a stunt saber? I've got an Apprentice V4 and I want to make sure the electronics are secure while I'm duelling with it.
I have some 1" OD PVC pipe which I think could provide a decent basis for the chassis. I imagine that I would wrap it in tape to make sure it fits inside the hilt snugly, but not too snugly.
I want to diffuse the kinetic energy from hits so that the battery pack and its wired connection don't get bashed around too much.
Any advice?

[chalion]

I've not been able to find anyone who posts about how to make a chassis for US hilts, but there are people who 3d print them. I've found that 1.25 OD pvc thin walled works ok for stunt sabers. The AAA battery packs fits snugly in it.

Here's some pics from a few years ago with my Archon v 3.1:

[Tai Chi Chuan Wijchen]

Although I like the idea of a chassis, and I'm definately will look up the 3D printed one just out of curiousity. This is my method of fixating the batterypack:

<a href="http://www.youtube.com/watch?v=S4Mz4D-l7Nw" target="_blank" class="aeva_link bbc_link new_win">http://www.youtube.com/watch?v=S4Mz4D-l7Nw</a>

[Samhain138]

I like the PVC idea for stunts, I'll have to try that.

I use a 3D printed chassis in my Flamberge and my customized Dominix.

[chalion]

Some 3d printed chassis aren't made the same as others though. Also, the Delrin made chassis are much stronger and take more abuse then the printed ones could, but cost much more unless they're mass produced.

I've been also able to make some from fibreglass resin composites, but it's messy and usually outside the ability of the home builder.