Noob's first saber

[Malthazar]

So here is the deal, I want to make my own lightsaber out of pvc tubing and then buy the blade and electronics from the wonderful people at Ultra Sabers, but i dont know the exact dimensions i need. So what i would like to know is what should be the inside and outside diameter of the pvc pipe i get and what type of paints should i use. I would also like to know what would be the best way to add more pvc onto the outside to creat things like claws on the emmiter and what not. Thank you ahead of time 

[Moderator Nightwing]

I cannot answer all of your questions, but hopefully I can get you started.
For the inner diameter, I would recommend AT LEAST one inch.  That is the standard for blades, and should leave you with a decent amount of room to fit everything in.  As for the outer diameter, that is really up to you.  If you think you would want a thick saber, then get a thick OD.
I think (not an expert so I cannot say for sure) if you are looking to build a dueling saber, claws may not be the best idea, especially for a PVC saber.  Your options to add claws (or claw-like extensions) would be some sore of adhesive, or screws.  Any adhesive will fail after some time dueling, and screws run the risk of cracking the PVC.
Concerning the paint, I have never painted a saber, so I am not familiar with what the best options are, but I'm sure someone here can help you out.
I'd say skip the additions for the first one, start simple and build up, that's what Ultra did!

Best of luck!

[Jenny]

Actually, a 1" inner diameter will be a really tight fit on batteries and so forth.  You probably want closer to 1.25" if you can get it.  More is better, within reason.

[Manroon]

I've found if you can get some 1" ID, it seems to slide inside of some 1.5" OD pipe. Do that for a blade and LED holder, and then it leaves you with lots of room for the batteries and etc. Plus, 1.5" OD is roughly the standard for most sabers it seems, so it's much the same to hold as several of the stock FX hasbro or MR sabers, or many MHS hilts. Hope that helps!

Oh, and for paint... sand the outside of the hilt, hit it with primer, and then coat it a couple times with some Krylon spray paint. Should get the job done nicely.

[Master Bluespike74]

So here is the deal, I want to make my own lightsaber out of pvc tubing and then buy the blade and electronics from the wonderful people at Ultra Sabers, but i dont know the exact dimensions i need. So what i would like to know is what should be the inside and outside diameter of the pvc pipe i get and what type of paints should i use. I would also like to know what would be the best way to add more pvc onto the outside to creat things like claws on the emmiter and what not. Thank you ahead of time 

I am in the process of building/finishing 3 PVC sabers.  I cannot get a AAA battery pack to fit inside a 1" piece of PVC.  I have heard people doing it with thin wall but I would not recommend thin wall. 

Here is some of the things that I have used:

1.25" OD SCH 40 PVC for the hilt. 
1.25" PVC Coupler for the Emitter.
Brass Threaded Wood Insert will hold well in the PVC and will hold your blade retention screw.
Drill a 7/16" hole for your Guarded Switch. 
Measure a piece of 1" PVC that will go from your switch hole to the halfway point of your emitter.  This will give your Mid-Grade Blade a nice resting point with very little play.
Use a 1.25" PVC Cap for the Pommel.  A self threading screw will hold this into place.
You can find Plastic Spray paint that adheres well to PVC as long as you clean it with Spirits prior to painting.

I actually have 2 videos (although not very detailed) of my Red Saber that I made. 

Although 1" SCH 40 PVC fits well inside 1.25" SCH 40 PVC, I could not get 1.25" SCH 40 PVC to fit inside 1.5" SCH 40 PVC.  Weird I know but all of this PVC was bought at the same section of the hardware store.  To add claws, use the coupler that I mentioned as your emitter and the brass wood inserts can be bought in different sizes.  Find out what size screw is needed for the War Glaive or Raven Claws and then buy those inserts.  You can attach them (I believe) with very little problems. 

Finally, when you are done with your build, you must post pictures.