Hi. This sounds like an epic first project. Before we start answering your questions... have you at all considered looking at the complete empty hilt packages or individual build your own saber parts on the US sales site ? Your very first customization/build experience should be fun versus worrysome and a more easy to complete project without damaging pieces sometimes beyond repair/useability. Blown sound boards can be costly. You could create a 3D shroud and other decorative modifications.
Let us know if you are a newbie or an experienced at finer soldering, electronics, tap & drill, retention screws, threading, dremel, etc.
Hi Dauntless,
Many thanks for the insights. My expertise with soldering and electronics would be light, and dremel would be nil. To be honest, building a saber was a testbed to learn and develop electronics and machining with a fun end-goal to keep me focused. My colleagues at work are all deeply experienced engineers, and I am swapping biochemistry lessons for engineering lessons.
However, your point about enjoying the first build is well taken. I would be well amenable to focusing on the machining aspects of the shroud rather than the electronics aspects until my soldering and electron control skills develop. Is there a plain hilt you would recommend that can be supplied with all the electronics packed in, but is as plain and narrow as possible to enable it to be encased in an outer shroud without creating an outer diameter akin to a can of beans?
It would still be useful to know the recommend internal diameter of the electronics housing, and appropriate threads, as I hope to ultimately build something from scratch in the future, but will first need to build it in a 3D CAD software package.
Deeply appreciate all insights and advice,
Many thanks!!