I can not express how appreciative I am that you posted these awesome pics! You've given me some really interesting ideas for the next two sabers I plan on getting (the Overlord and the Archon v2). I have a question though, I see that TCSS blade holders don't come with a hole already drilled in them for the blade retention screw and that you in fact have to order that seperately, so my question is what size Drill & Tap hole did you get put on those blade holders from TCSS? Does it even matter? I'm so afraid that if I get this done I'm going to get the wrong size.
I believe I requested the drill and tap to be 8-32, and it fits the set screws that came with all of my Ultrasabers quite nicely.
Also I see that TCSS has several different variations of black, which one did you get?
I had my emitters and connector powder coated with flat black (or "Black Matte Tuscan"). I know many people prefer the look of the wet black, which essentially has a glossy finish, but to me the matte finish of the flat black is much closer to the black anodizing on the US hilts (which aren't really glossy at all). You can see in my pics how close the colors match.
That being said, if you wanted an exact color match US now has a black anodized vented coupler that sits flush with your hilts.