First Mod, in progress - log (pic heavy)

[RevanReborn]

Hey everyone .  For my first mod, I imagined what my saber would be like if I was a legendary Sith emperor.  I wanted to do this first project right from scratch using stuff from around the apartment/ hardware store, and actually make the parts etc.- I'll save the pro/ stock parts for the next project.   

I've got a TON of work left ahead of me for this, but here's a glimpse of the rough work I've done so far and a mini step by step:

I decided to use my emerald catalyst (with red illuminated switch) because of its elegant/ regal, yet mean, look.

I started by making cardboard templates from paper towel tubes like I saw in srams post for pvc shrouds, and applied them to a section of pvc and also some brass tail-pieces / pipe inserts by simply tracing.  Then I used tape to make all the lines nice and straight /fine tuned. 






I cut out the pvc piece, which will form an outer/ thicker shroud to make the av switch low pro, and a brass insert, which will form an inner shroud, creating a layered look, defining the grip area, and giving me a hand stop down by the pommel. Did the cutting with a dremel and cutting disk, round burr, fine pencil pointed burr, and various grinding/ sanding bits. I had to remove a ton of material from the inside of the pvc to fit lol.  A drill press and drum sanding bit came in handy, but the burr also helped. 





I thought about cutting a fancier pattern into the back of the inner shroud, but decided that the points would look the best, and execute better in the end.

Then I repeated the process on another insert to overlap the outer shroud, giving me another flange at the choke right before the emitter, for a regal, bad ass look and great hand stop.  I cut a seam down the spine of this piece once I had it shaped, to allow it to fit over the larger pvc piece, and I will be embellishing this seam and incorporating into overall design.










I did some more work shaping and fitting the pieces.






I've got a ton more to do- creating, cleaning up/ fitting pieces, tapping holes to secure them, as well as for more blade retention, plus I'm going to do the grooves in aluminum black, and also re- finish/ engrave/ paint the hilt... Yikes I better get back at it lol!  Keep you posted, MTFBWY

[magik0012]

Very cool mod! Definitely keep at and keep posting pics! And have a point!

[RevanReborn]

Thanks magik, dauntless . Appreciate

[RevanReborn]

Started to do some of the more detailed work on the pieces that will form the outer shroud- doing a red sith symbol inlay above the av switch.




Keep u posted- MTFBWY

[Jamie Stick]

That's really some epic work there.

[RevanReborn]

Thanks for the compliment/ words of encouragement, Jamie!  It's great motivation to hear from from people on the forum, keeps my mind on task- appreciated .   Also, love the quote in your sig-  one of the best lines ever. 

[MavRick]

I really like the looks of the gold shroud on the silver hilt! that looks sweet!

[RevanReborn]

Thanks, MavRick, appreciate I've got a lot to do still, but I'm happy with how it's turning out so far- I'm going to dramatically refinish the hilt with gun blue and aluminum black, giving it a really dark, even weathered, type look, and I think the contrast of the brass pieces will really look sharp against that.  I'm going to do some kind of buffing/ polishing job on the brass still, but I'm trying to decide about possibly applying some kind of pattern or finish in the process (like polishing with a silicone wheel free hand with dremel in tiny circulars over and over  creates a finish that's almost like shiny fish scale- or brushing the finish and buffing/ polishing nice borders- etc)

Also I'm probably going to be doing a kind of mean, jagged pattern engraving on the hilt and applying metallic gold and bright red down into the engraving (I'm picturing like force lighting pattern or something but in red and shiny gold going all over the dark finish hilt!). Can't wait .   Keep u posted, and MTFBWY

[RevanReborn]

Thanks for heads up Dauntless:) point for the help.  ya I suspected as much, it's a different batch of chemicals- i think it's copper sulfate that primarily does the job in gun blue, and I doubt that works very well on aluminum- but I was asking a friend about it and got a hunch that we can combine some stuff and come up with a solution that will react with/ deposit something on the aluminum in a similar way.  But I'm still waiting on the info from the people who actually know the chemistry, so who knows, we'll see?! Lol I'm not doing anything without the go ahead so I don't blow myself up or make a big cloud of poison or something lmao that'd be just my luck too   actually I just might pm him either way, I'm getting ansy waiting to hear from my chemist buddy and I think it'd be cool in the meantime to hear from someone who's worked with the stuff before, even if on other mediums.  Who knows maybe he's tried it anyway just to see, and can warn me about explosions etc. lol

[RevanReborn]

HAHAHAHA!!!! Well said Daunless, lol . I guess I walked right into that one didn't I lol.  Onterrible... (sigh) well, it's home anyway lol.  Actually I can't complain I guess, I live right at the southern most tip (or what's left of it anyway- eroding alarmingly fast) where we actually have a cool mix of Eco systems since we sit low next to Great Lakes- we've got cool wet lands thing kick'n here with marshes etc.- but ya totally can't argue with you lol otherwise I think it's just a bunch of fields and then TO and then a bunch more fields, and then some rock and bush in the north:).

And will do as far as saber goes- tho can't promise will turn out blue lol, but my source seemed to be saying that there would actually be different ways of chemically 'refinishing' aluminum, or achieving dye like effects other than the blackening you get  with metal touch up.  tho it didn't sound like something he had given any thought to before I asked, to be fair- so we'll see

[RevanReborn]

Hey everybody

Been super busy lately, not a lot of time for the project- but managed to pick away at the outer shroud a bit more before bed today (I work night shift). 

Everything still needs to be cleaned up a ton and tweaked, plus I've just got so much work on this one that I haven't even begun yet.



The sith inlay's still messy ATM but I'm happy with how will turn out.  Did some vertical grooves, which I will be sanding down deeper and blackening to match the grooves in grip (which I'll be blackening too).





Excited to get to work on the refinishing, engraving, thread tapping, etc.  Keep you posted, MTFBWY:)

[RevanReborn]

Hi all . I got the pattern I'm going to engrave on the inner shroud marked out... Hmmm, maybe a little ambitious considering I've never engraved anything in my life lol, but you gotta learn somehow!  I'll have to mess around on some scrap before I start but I guess if it's worth doing it wouldn't be any other way lol.  Keep you posted, MTFBWY.

[magik0012]

Oooh.. I like where you are going with the plans for engraving.. that will look super sweet! Good Luck!

[Drahcir]

Definitely practice the engraving a lot, it's really easy to slip on the curve.

[RevanReborn]

Thanks so much everyone!  It's thanksgiving time here in Canada, which is fitting, because this community is definitely one of the things I'm thankful for- you guys are the best .   Also thanks for the suggestion/ advice Drahcir- will do, for sure . 

Keep you posted, MTFBWY.