sjorsjo.... Sorry for the late reply mate... had some water issues around the house today
In reference to the measurements you asked for.... I can't get hold of imperial sized PVC down here (australia.)
Everything we have is metric. however.... i can tell you that you will need something as close as possible to 1" inner diameter for the blade and led module, something like 1" schedule 40 Electrical conduit should do the trick. once you have a length of that.... measure the outer diameter... whatever that outer diameter is, thats what you want the inner diameter of the hilt to be.. make sense?
Now that you've purchased some stuff i'm sure you'll be all over it and you will be able to let us know what your issues were, etc... along the way.
And just for your information... i've never built a working saber.. I cant buy the PVC here in the right sizes to do it. So your ahead of me
If you have any issues receiving support.... just PM me... but i'm sure we shouldn't see that problem.. you may just have to post in the OFF topic section... as i did with my practice sabers!
http://www.saberforum.com/index.php?topic=55.0