I'm planning to build my own custom saber eventually. I've had some ideas for different designs, most of them are similar to notable hilts, like Vaders, Starkillers, Obi Wans, and a few others. So I was wondering how best to go about this. I know that US sells saber parts, but I was wondering if there are other places to get saber parts. Any help from people who've done this before is much appreciated.
Check out this thread, especially the first page. Getting to know all the parts you need is a great start.
http://www.saberforum.com/index.php?topic=11521.0The Custom Saber Shop also sells parts and they have a bunch of videos on how to assemble what they sell. Bonus that some of the parts like pommels and emitters are compatible with Ultrasabers.