Kal's Prophecy V3: Ha no Kage (Jacen Solos Lightsaber)

Alrighty so I'm pretty much done customizing, the only thing i really have left to do is find a cool thumb screw to fit into the hole that doesn't light up because thats where the LED module sits and it will help keep that stable. But here's what I did, and, and why. So first I bought an Archon Pommel because it added the length that was better suited to the low choke grip that Jacen typically uses. It also gives a more complete feel to the lightsaber as it has inspiration taken from Darth Vaders hilt (the shrouded emitter) and from Luke's hilt, which is what the pommel adds. To paint it, I bought all Rustoleum brands, but I got Self Etching Primer, Ultra Flat Black, and Matte Finish Clear Coat. I also bought painters tape with edge lock. In order to get the fluting covered I covered them with painters tape and pressed in with a Q-tip. To cut around them I originally cut with the blade of my Xacto knife pointed down but quickly realized it was scoring the aluminum. I found that if I ran the blade flat against the corners of the fluting it scratched the tape and eventually cut it leaving fairly nice edges, but it was still a good idea to press the edges with my thumb to smooth them out. Then I sprayed 3 coats of primer, 3 coats of paint, and 3 coats of clear coat at 1 hour intervals between coats but 24 hours between each kind of paint (does that make sense?). After the last coat of clear coat I waited 15 minutes then removed the tape because if you don't it's more prone to chipping if you let it fully dry. Then with the original pommel i put on #218 black O-rings from Home Depot. The original pommel helped because the rubber stretches, but it's hard to get on and that made it easier. Then I had the idea to put the color discs into a container that comes with sanding discs for my Dremel. This is really nice because it means I can have everything on hand to change the color of the blade and it also means the I cut the rattling of electronics in the hilt. Lastly I stuffed some gray packing foam I had laying around into the pommel. This further cuts down on rattling and finishes the look since the pommel creates more space in the hilt and has holes cut for sound and covers them. Over all I'm very pleased and can't wait to design my own saber for a friend to machine and try to get Emerald and Obsidian electronics installed in that one.