I thought I'd share some knowledge here, this is a simple way that I make my PVC shrouds for my sabers. I don't have all the latest or greatest shop tools, and I doubt most of us do. This is a photo tutorial, I'll try to narrate the best I can, bear with me...
Note this only works for US sabers 1.45" in diameter, most of the lower end, more affordable sabers, should work. V3 initiates/dominix/aeon sabers only. V2 sabers are too narrow for sched. 35, sched. 40 may work for the V2's but I'm not sure.
To start here's the materials I start with:
And the tools that I do have to use. More commonly accessible to most of us I hope. What you don't see are safety glasses and a dust mask. I absolutely recommend using them. I did, even though they aren't shown here.
First step, cut the edge as straight as you can. I use masking tape to get a straight edge. Then draw on the PVC overlapping the tape with a sharpie. Remove the tape and cut along the line you just drew. I use my Dremel with a thin kerf emory cutting wheel to make all cuts in the PVC.
Then get a cardboard paper towel tube. Flatten it in half, draw your design on it, keep in mind it will expand when you make the tube round again, so draw your design with that in mind, you want to avoid making it too small or too big in proportion to the PVC.
Cut out your design with scissors or a razor. If you design it in such a way it should be symmetrical when you make the tube tube shaped again.
Open the tube so its tube shaped again, cut your design straight down the spine, put it around your PVC, then tape it up. Then trace the cardboard tube on the PVC.
I use my emory wheel, and sanding wheels to cut and finish the PVC.
After its cut use the sanding wheels to clean up the cuts. You will probably spend a lot of time on this step.
The final piece should resemble your cardboard cut out.
Then after its all clean and pretty place it over your saber it should fit nice and snug. If its tight, use some sand paper on the inside of the shroud.
You can then color it any way you like.
Here's another shot with another lower shroud I made using this technique.
I'm going to try this with a metal sink tube soon, I'll reply back as to how well or not it works.
I hope this helps anyone who wants to try making custom shrouds! I'm always happy to answer questions, and I'm always open to criticism, and of course praise!
Srams, that is AWESOME. I really like the (relative) simplicity of the operation. Have you tried the procedure w/ other materials? Just wondering about tedium vs. medium (sorry, not trying to be a poor poet...)
