Saber Forum

So, while I'm waiting to gather the funds for my next order (graflex CE emerald n also a saber specifically for modding, TBD) I'm gonna be doing a bunch of work on my main duelling saber, my stunt dark sentinel LE.  For the mod i did before this one, i had a really specific idea of everything i was gonna do- i could really picture the saber so it was just a matter of making it happen.  For this one though, I'm gonna just kinda go with the flow more- just let a lot of the stuff happen as i get into it lol see how that is for a change. 

I DO know some aspects for sure:

-going to be engraving the entire sith code down the length of the hilt

-going to be swapping the battery pack for a rechargeable usb power bank a la CJ Nihilus, as well as possibly creating a usb port in the hilt for recharge without removal, or maybe some type of quick disconnect for quickly swapping precharged banks

-going to be creating some kind of small attachment/ detail that looks similar to an activation box etc. in size and appearance, only it will house electrical pins and a sort of faux access port to look sweet and lend realism etc.

-i'm probably forgetting stuff, but its all good since I'm just shooting from the hip this time anyway lol

So here's some ground work I've done so far:
sanded the finish to have a nice complex background/ slate for the engraving to go over- wanted it to stay nice and dark but have a sort of grain, or ribboned type look
(http://i736.photobucket.com/albums/xx2/major_major/6D3332E6-2AA2-4308-9D0F-75D89FD39FD0_zpseugiqmli.jpg) (http://s736.photobucket.com/user/major_major/media/6D3332E6-2AA2-4308-9D0F-75D89FD39FD0_zpseugiqmli.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/AE3D5AD5-4267-44A0-91B0-4B09427FC042_zpsjqdue6r2.jpg) (http://s736.photobucket.com/user/major_major/media/AE3D5AD5-4267-44A0-91B0-4B09427FC042_zpsjqdue6r2.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/D7B4A8F5-5679-4098-B712-7E3D858C8634_zpsp7vh5hei.jpg) (http://s736.photobucket.com/user/major_major/media/D7B4A8F5-5679-4098-B712-7E3D858C8634_zpsp7vh5hei.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/F28EF79A-5DE3-49A7-98F0-3E8F3C94D04C_zpsh4csulsq.jpg) (http://s736.photobucket.com/user/major_major/media/F28EF79A-5DE3-49A7-98F0-3E8F3C94D04C_zpsh4csulsq.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/8C3F3B03-5649-4A8B-B502-F7EC28213C2F_zpsnj9gk4sv.jpg) (http://s736.photobucket.com/user/major_major/media/8C3F3B03-5649-4A8B-B502-F7EC28213C2F_zpsnj9gk4sv.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/00C2E649-DEC1-4988-BE86-6F1D846520ED_zpstrwtbg1w.jpg) (http://s736.photobucket.com/user/major_major/media/00C2E649-DEC1-4988-BE86-6F1D846520ED_zpstrwtbg1w.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/16A06DC3-CA80-4C62-97E1-201F5863D0BA_zpswprfztuf.jpg) (http://s736.photobucket.com/user/major_major/media/16A06DC3-CA80-4C62-97E1-201F5863D0BA_zpswprfztuf.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/879B2277-243B-4EDB-A697-4BB018930469_zpsxsdpd1pt.jpg) (http://s736.photobucket.com/user/major_major/media/879B2277-243B-4EDB-A697-4BB018930469_zpsxsdpd1pt.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/3E436114-A532-4F62-B557-8A982D9E05BE_zpsf62lnix1.jpg) (http://s736.photobucket.com/user/major_major/media/3E436114-A532-4F62-B557-8A982D9E05BE_zpsf62lnix1.jpg.html)

next step was to plan/ space out the sith code i'll be engraving using masking tape- it's just way to much aurebesh to leave it to chance that it'll end up spaced out correctly as i go.  i know everybody's prob like "hey man, why not use sith script?!"  but i just like aurebesh for one, i know it so much better and i think it's the most recognizable, plus sith just wouldn't execute well hand engraving with my skill level (that'll be something to get laser engraved in future):

(http://i736.photobucket.com/albums/xx2/major_major/D97F6E57-895B-441A-B012-0F9CAC53C581_zpslqbmdd5m.jpg) (http://s736.photobucket.com/user/major_major/media/D97F6E57-895B-441A-B012-0F9CAC53C581_zpslqbmdd5m.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/5C159DC4-88CF-444F-AD39-0EA1AA00D412_zpsxs3zpgbo.jpg) (http://s736.photobucket.com/user/major_major/media/5C159DC4-88CF-444F-AD39-0EA1AA00D412_zpsxs3zpgbo.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/745908B7-0A21-4B68-9678-DAB315E9A524_zpszhlmgz1v.jpg) (http://s736.photobucket.com/user/major_major/media/745908B7-0A21-4B68-9678-DAB315E9A524_zpszhlmgz1v.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/0E62CC29-581F-4109-B2BD-A06BFEC03947_zps2qnka7bl.jpg) (http://s736.photobucket.com/user/major_major/media/0E62CC29-581F-4109-B2BD-A06BFEC03947_zps2qnka7bl.jpg.html)

next step, a little bit of engraving lol...  but it's getting late for today, gotta work tonight.
keep you posted, MTFBWY :)

Good thing i glanced back over this post!! i just noticed a spelling mistake in the aurebesh in one of the last photos: I've got 'cains' instead of 'chains' lol!!  needless to say i'll be proofreading this before i engrave lol, this was just for the spacing... but still, jeez lol. 

Looks pretty interesting. Im trying to come up with an idea on how to cheaply make an activation box as well so i will be following along

Sent from my SM-G900V using Tapatalk

You can cut a switch sized hole in a TCSS graflex clamp.

Revan, what do you plan on using for the inscription? I'm going to be making an ancient type saber soon, and that would make for some awesome detailing. Just not the Sith code; I don't want to steal your idea.

Just bought a car and im in college. Sub $20 is what im hoping for. If i cant come up with something ill just buy one of those though.

Sent from my SM-G900V using Tapatalk

Hey everyone- thanks :).  To answer your ? Monobus I'm gonna be using a little electric engraver (not expensive).  Basically like a little tattoo gun you can adjust the depth on, tho I've found the depth is really more determined by how you actually work the engraver, rather than what it's set on.  If you haven't seen it, I did some simillar engraving, albeit not as much, in a previous mod:
http://www.saberforum.com/index.php?topic=25425.0

Only diff is there I did it on yellow brass, so I put black down in the inscription- here I'll be doing on black anadized hilt so will already have the silver on black look, but I might put red down into the key words (like passion, strength, power, victory, the force etc). 

By all means, there's no worries about using people ideas here :).  It's one of the great things about the forum- I bet the code would look amazing on a relic.  Actually that mod I linked has arcane/ relic type influence as well. 



Hey Halnis- I know your pain well, lol- I've never had to scrounge/ be more resourceful than the five years I moved away to university!  Just look at it this way, by the time you're out you'll know you can get by on anything/ make it through any hard times lol!  Def stay tuned- I'm gonna be doing this add on piece right from scratch- so it will likely cost a matter of a couple dollars max when all said n done :).  I've already got a pretty good idea of how I'm gonna do.

Keep you posted- MTFBWY

Nice Rev. That will look insane. And I mean insane like, scribbling words on your asylum cell walls. I like it ;) Can't wait to see this finished.

Nice idea's Again! look forward to seeing this develop. The light weathering already done looks good, natural like it has been used hard .  I also like the aurebesh font  lettering myself, plan on doing my jedi name ( created from the post here in off topic) scrolled  or possibly etched on my menace, haven't decided ( along with other mods) when the up to 15 weeks backlog or more lets it be on its way to me.


 So true, myself only being a 4ish month long member, my thought is  if you have an idea, share, your not copying, its all about inspiration. thats the whole point , grow, learn, tap into your creative side for a  Group wide collective passion  Take Pride  ;D

Lol I engraved Aurebesh on my yari Pike today. Its a nice font and makes any word look awesome. Also nice job fitting the sith code on the hilt.

(http://i.imgur.com/sYK4XVo.jpg)

Thanks guys!  Ya, totally will look deranged I agree Antron :).  And I agree completely Bulvoy- if I ever see people doing things like I've done on the forum, I'll be totally pumped/ stoked, since it will be a sign of something I was able to contribute to the community- and i know I've taken so much knowledge/ inspiration from this community so it'd be nice to give back :).  It's what makes this place great.  That looks sweet kezeroth! 

Your other saber looks awesome! I love the look of it. I might have to look into one of those tools. All I have is a dremel, albeit with a ton of attachments. I don't trust it enough to try and inscribe on one of my USs though.

thanks Monobus :)  ya i think its a good call looking into the engraver- you can get them cheap, and for our purposes they're more than quality enough.  there's all different styles, like little pen engravers that i bet would handle great?, mine's a wired (not cordless) larger unit, about the size of a really small dremel, but it's cool it's quite comfortable to me my hands are on the larger side.  Maybe its just me but i'd be worried about controlling the lines for detail with the dremel's rotary motion- engravers puncture, their motion is straight up and down.  I might be wrong tho maybe people do engrave with dremels?  Kezeroth, did you use a dremel for that inscription?  it looks great.

I'm debating using a scribe, a little manual pointy tool, and going back over the engraving once it's finished and embellishing it on this project?  Dunno, on the one hand it could look really cool.  On the other those will be some really small details/ lines- it'd be a shame to make them look all clumsy if i can't achieve the right amount of fine detail with the tool?  like its hard to explain but it might just oversize and make it look crappy, like going over something you wrote all finely in ink and quill with a big 'ol gigantic crayon lol.  still undecided, but i can do the engraving and cross the bridge then- hopefully i can just approach it cautiously and see if going to work :).  i think if i could pull it off i could really put an extra touch of style to the engraving and, tho it might be on the subtle side, would be totally cool/worth it.

i left the lower choke between the grips and the switch area blank because that's where I'm gonna be putting one of the little fabrications i'll be doing- just a little add on to the body of the saber for looks- and that spot is strategic, since my hands aren't often there.  but in any case ill be sure not to wreck the grip of the hilt.  any changes i make to the profile etc. of the saber are gonna jive with grip n all that, since this is my main duelling hilt these days.  i really like the feel of the sentinel, so whatever i do will preserve or improve its fit to me for sure. 

can't wait to get back at it, just got a few busy days to get through first- but I'll be back on it soon :)  keep you posted, MTFBWY   

@RevanReborn I used a dremel engraver i bought on amazon for like 15$. Difference between a engraver and a normal dremel is the mecjanics. I know someones wondering about the difference so i might as well say it. Normal Dremels spin the attachments & engraver dremels vibrate. Both have buttons or switches to change speeds but Ive found the engraver words really nice with small details.

Agreed, Bulvoy . . . +1 to you & Rev :)

wow that sanded look is beautiful

Thanks Morgoth136 :).  There have been some really aweome sanding jobs in the last little while from members like thereisnostrike and telepathictraffic etc.-  def worth checkn out.  MTFBWY

il have to check out their stuff. what did you use to sand it? a full sander? block? paper?

I just used 120 grit sand paper, cut into strips of varying thicknesses (some narrow slivers, some as wide as the whole body section I was using it on).  I'd put the strip in my open palm, place the saber in the palm aligning the area to be worked on up nice n straight with the sand paper strip, then close my hand- wrapping the strip over that area of the saber and spin nice and easy, concentrating on making a nice straight grain/ fade pattern.  I'd stop often to check how it's looking, and to go over with a fine grade contour sanding sponge to blend all in/ together.  The sanding sponge was such fine abrasion that it almost wouldn't even wear the black down in colour at all, it kinda just smooths the grain/ softens its appearance. 

It so fun to do :).  Was tempting to keep going and going lol, but I really wanted the look to stay as dark as poss on this one.  Telepathictraffic has a video of the process on his post so you can see how simple it is to do- pretty much same technique, only thing I did different was maybe press bit more lightly when spinning/ sanding, but makes sense because I didn't intend to take nearly as much black off as he did.  Pressing hard will create wear a lot quicker, but less forgiving if not keeping the grain straight/ consistent.  Lightly sanding can still remove any/ all finish, and is more forgiving in that sense, since it happens much more gradually that way, but obviously it will take longer. 

Didn't have a lot of time today before bed, work still crazy... But hey, it's almost the weekend!!  I did manage to get a little bit going on one of the little fabrications/ accents I'll be putting on.  This isn't the one that will go in the lower choke that I mentioned before- this goes on the side of the grip section, reminiscent of the positioning of the circuit card in a graflex only a fair bit lower- it's going to contain electrical pins, and a faux switch, as well as a some kind of faux port, with wires coming out and running along the hilt and down inside through another spot (a la kylo or even the screen accurate MPP) . 

This piece itself is like the little activation box or main module that all the other little accents are attached into- it's a REALLY solid hunk of stainless almost as thick as my finger lol!  Gonna carve a very shallow silhouette of this base piece into the hilt itself when comes time to attach, so that it sits nice and seemlessly against the grips.  Before I can go any further I gotta decide if I'm attaching with pan machine rivet looking screws or using socketed machine screws and recessing them into these holes I just drilled so they sit down in/ flush.  I really like the way both would look and honestly can't decide lol.

(http://i736.photobucket.com/albums/xx2/major_major/D6835C42-F555-40BB-BC62-2121D4D380DB_zpsdepesooa.jpg) (http://s736.photobucket.com/user/major_major/media/D6835C42-F555-40BB-BC62-2121D4D380DB_zpsdepesooa.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/20B043B0-F973-4AE4-A08C-7FD1447EE824_zpseadi4r2i.jpg) (http://s736.photobucket.com/user/major_major/media/20B043B0-F973-4AE4-A08C-7FD1447EE824_zpseadi4r2i.jpg.html)
(and believe me my fingers aren't small lol, nice solid hunk o stainless)
(http://i736.photobucket.com/albums/xx2/major_major/170902B9-7F2B-41B4-A83F-6488AB08ECE5_zpsle26jijd.jpg) (http://s736.photobucket.com/user/major_major/media/170902B9-7F2B-41B4-A83F-6488AB08ECE5_zpsle26jijd.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/7F7360DF-B182-40F7-A4E5-C5ED2B3F943E_zps49adurra.jpg) (http://s736.photobucket.com/user/major_major/media/7F7360DF-B182-40F7-A4E5-C5ED2B3F943E_zps49adurra.jpg.html)

Somewhere deep inside a little ocd side of me I didn't know I had really wanted me to centre this accent in the grip section, but after way too much time thinking about it and testing the grip lol, I decided that 1) this is gonna be a sith saber, one with wires stickn out and jagged inscription all over it etc... Not centred is decorum and 2) the functionality simply/ automatically trumps anything since this is my life on the battle field lol.  Where I'm putting it up high on the grips I can't even tell you how AMAZING this thing grips!!  My trailing hand just gets LOCKED on in a way I've never felt with any other saber (well I guess that makes sense since I've never tailor made a grip section for one before lol).  The cover tech fits right under my hand,up in the underside of my palm on the bottom, and the top side of that same hand is butted up against the side of this chunky base-  it's got nowhere to go, it's such a good feeling, like its nestled in it's own cozy little spot lol... AND READY TO DESTROY!!! Lol

Keep you posted- MTFBWY :)

So, I mentioned in an earlier post about repurposing stuff or using cheap hardware store stuff for a lot of this.  The Easiest way to find cool parts I know of is to take apart old junk you have lying around- in this case an old phone.  I got caught in a crazy downpour waking home from work one morning and the battery exploded lol, so I made like Rey lol:
(http://i736.photobucket.com/albums/xx2/major_major/AE775C94-C693-4136-9135-137FF28BB99B_zpsshwl9gdx.jpg) (http://s736.photobucket.com/user/major_major/media/AE775C94-C693-4136-9135-137FF28BB99B_zpsshwl9gdx.jpg.html)
Picked through everything, and pulled out a few gems that seem to suit this piece and what I've got planned for it- and began planning the positioning of things:
(http://i736.photobucket.com/albums/xx2/major_major/6212A2F9-5C3A-4FF0-B5B2-A687080D9C78_zpst3pre5x3.jpg) (http://s736.photobucket.com/user/major_major/media/6212A2F9-5C3A-4FF0-B5B2-A687080D9C78_zpst3pre5x3.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/1F54218C-0FAD-49FB-B0DF-3104B360D0F1_zpsff6wk4oh.jpg) (http://s736.photobucket.com/user/major_major/media/1F54218C-0FAD-49FB-B0DF-3104B360D0F1_zpsff6wk4oh.jpg.html)
At time of pics there was still a little snaggle of wiring harness hanging out from the edge of that little aluminum plate, I've since cleaned that up.  There's a little chip attached to the underside of the plate, which gives it a really cool look when glimpsed from the side or underneath.  I'm just gonna metal epoxy most of these little bits on, it's easy but it's also the best way to secure- this stuff won't budge once it's adhered, theyr such tiny/ light pieces and the bond of that stuff is so strong there's no way it'll be jarred loose by clashing blades.  An actuall blade strike could do the trick, but if a swing is connecting to that area of the hilt then I'll have bigger problems than some free/ easily swapped bits and bobs lol.   

If you look down on the side of the chunky base that will be screwed into the hilt, right under where the little plate sits, you can see a small black dot- I marked where I'll be drilling a hole to tap and insert a little knurled control knob looking thingy.  On the other side of the base, I'll be making/ tapping two more holes very close together for some electrical pins, I just don't want to pay for the pins, so I'm waiting to come across some fluorescent lights.  Shouldn't take long, they're in just about every building around, so somebody's always replacing theirs- and each tube has four brass electrical pins (two on each end cap).  Soon as I score the garbage light bulbs I'll have at least four pins :). 

Also, next to the pins, I'll be attaching a little port (headphone jack pulled out of phone), out of which some wires will run up along the hilt, eventually making their way to the other add on feature I'll be doing, where they'll then go down into the hilt.  It's kind of hard for me to explain, or probably for you to picture, where I'm taking this part, but I think once I've got it more complete you will be able to see the look im going for :).  Actually now that I can see exactly how it's going to be done I'm pretty excited- gonna be gnarly!  Keep you posted- MTFBWY.

Good stuff as always Revan!

Hey wait... A dark Sentinel in BR with a circle blade plug.

Did you rob that from Darth Arlo?!

Thanks Greg! 

SHHHH! Don't say that too loud lol, arlo hasn't noticed yet ;). 

I decided to recess the screws on this activation box piece:

(http://i736.photobucket.com/albums/xx2/major_major/0A190876-99AC-4EC4-B008-249B07619B54_zpsb3txdtnd.jpg) (http://s736.photobucket.com/user/major_major/media/0A190876-99AC-4EC4-B008-249B07619B54_zpsb3txdtnd.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/893B74EF-B46F-47AA-A7C8-0233F3238C61_zpsxzetwbif.jpg) (http://s736.photobucket.com/user/major_major/media/893B74EF-B46F-47AA-A7C8-0233F3238C61_zpsxzetwbif.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/9F5EFFBD-2E65-4D3E-A80F-F35A78F6578E_zpsifnorina.jpg) (http://s736.photobucket.com/user/major_major/media/9F5EFFBD-2E65-4D3E-A80F-F35A78F6578E_zpsifnorina.jpg.html)
Keep you posted- MTFBWY :).

Arlo is not gonna be happy. But maybe he just thinks you're improving his glorious weapon.

After seeing it, recessing the screws on the actbox seemed to be the right move. Really digging this build. Can't wait to see more.

Sent from my SM-G920V using Tapatalk

Thank Antron :).  Appreciate it.

Oh, and Greg, dude you have no idea how right on the money you are lol!  It's hard to explain, but once you've spent so much time around arlo, you can totally tell that he looks at everything and everyone as if they belong to him- I've no doubt that's exactly how it is in his mind, he probably wonders why I spend so much time fussing over his shiny noisy metal things lol!!

Well, I don't have a ton of progress on 'his' saber lol, but here's the bit of engraving I managed to sneak in (I haven't gone back over it with scribe yet):

It might be hard to follow along at the moment because I haven't put the base line on yet- will be a line running straight down the hilt so your eye can easily pick up the flow of text ( like the starting of one line of text and when it ends and you jump down to the next line etc.). Here at the grips/ pommel it picks up at:

"...broken.  The Force
shall free me."

(http://i736.photobucket.com/albums/xx2/major_major/75E68F9A-B20C-4073-9893-28C60D080757_zpstlexndc0.jpg) (http://s736.photobucket.com/user/major_major/media/75E68F9A-B20C-4073-9893-28C60D080757_zpstlexndc0.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/AFA463A5-1A0B-49BD-90CB-6AEC51DBDB99_zpshw6daurw.jpg) (http://s736.photobucket.com/user/major_major/media/AFA463A5-1A0B-49BD-90CB-6AEC51DBDB99_zpshw6daurw.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/35E81138-94CF-4F91-A852-AF08937D2C1D_zpsf76zsf03.jpg) (http://s736.photobucket.com/user/major_major/media/35E81138-94CF-4F91-A852-AF08937D2C1D_zpsf76zsf03.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/4F06838C-A285-4704-9869-1687C8E17AC4_zpssqvuz4az.jpg) (http://s736.photobucket.com/user/major_major/media/4F06838C-A285-4704-9869-1687C8E17AC4_zpssqvuz4az.jpg.html)

Thanks D7 :).  For sure, its gonna be a one of a kind!  This one's gonna look like mad sith science... but i guess thats kinda becoming a thing with me lol!?  I'm looking forward to doing some Jedi saber projects too tho i swear lol.  Keep you posted, MTFBWY.

Im highly intrigued! Ive loved following along! What was that hunk of steel before? Or was it simply a spare hunk

Sent from my SM-G900V using Tapatalk

thanks, Halnis :).  The hunk, I'm like 99% sure- and i've even double checked with the maintenance guy lol, was a spacer of some kind from the machine i run at work.  its not used any more thats for sure lol, was just in a box of nuts and bolts etc. I work at a commercial printing press... i can't really talk about it by name or in detail cause they're a bit paranoid about confidentiality, we sign agreements and people have gotten dinged before for seemingly innocent stuff on social media :(.  But its a really big operation, and the equipment there is constantly changing with technology, so its an amazing source of bits and bobs!  But there was nothing really special about it, just a nice shape that saved me a lot of cutting and sanding, nice thickness to give me freedom to attach a lot, etc- once you start visualizing and dreaming up things that'd look cool on a saber, you'd be surprised how easy it is to come across great parts!  You'll start seeing them everywhere lol, and you'll annoy everyone around you by stopping every two seconds everywhere you go, talk'n bout "oh, this would be sick for blah blah blah.." lol :). 

like seriously i can't even go near hardware stores anymore unless i've got time to kill lol.

I attached the control knob to the side of the activation box accent thingy lol.  I also got to attaching the little port (headphone jack out of old phone) where the wire will come out of, and i was a bit worried about the subtle torque, over and over again from the wire being slightly pulled taught under my hands gripping the saber, and figured it would be a bit too much for metal epoxy (maybe- stuff is strong) so i recessed a 6-32 socketed screw in through the back of the plastic casing and into the main steel box.  its not going anywhere now thats for sure :).  (http://i736.photobucket.com/albums/xx2/major_major/D479C231-D605-4260-A00C-22070B99D56D_zpsd481v3aq.jpg) (http://s736.photobucket.com/user/major_major/media/D479C231-D605-4260-A00C-22070B99D56D_zpsd481v3aq.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/55CF8ECF-E79C-47A4-8EC7-8D1368581C36_zpsjk2fr3ui.jpg) (http://s736.photobucket.com/user/major_major/media/55CF8ECF-E79C-47A4-8EC7-8D1368581C36_zpsjk2fr3ui.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/4D15B6BA-E7D7-4D1D-889E-739335B1C204_zpsdkh5coo2.jpg) (http://s736.photobucket.com/user/major_major/media/4D15B6BA-E7D7-4D1D-889E-739335B1C204_zpsdkh5coo2.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/BF82D5F2-D96F-4D2D-8E63-E9E209FE09B4_zpsbdax3tri.jpg) (http://s736.photobucket.com/user/major_major/media/BF82D5F2-D96F-4D2D-8E63-E9E209FE09B4_zpsbdax3tri.jpg.html)
I'm gonna be getting some edge connecter/ circuit card (like in the clamp of a graflex) in soon- gonna trim a piece to fit neatly on top of the main base, so that the little plate and wire etc. will be sitting on that, it'll really complete the look of this little accent- then I'll be adding electrical pins on the side:(http://i736.photobucket.com/albums/xx2/major_major/A138662B-81F8-40D1-928D-DFBE2F7EB205_zps6h430wpj.jpg) (http://s736.photobucket.com/user/major_major/media/A138662B-81F8-40D1-928D-DFBE2F7EB205_zps6h430wpj.jpg.html)
(sorry i had to create that picture on my phone while doing stuff lol)

keep you posted, MTFBWY :)

ugh, lol, i'm so bummed out :(.  I just found out that there's been another set back in regards to something I've been trying, and REALLY looking forward, to getting my hands on for a while now.  It's nothing for the forum, but it is definitely related to the hobby in gen- i've just had my sights set on something lol, and funny enough how it always seems to work out that way, when you really want something the whole journey of getting it's often full of little episodes of disappointment, frustration etc.  I'm sure everyone can relate, been doing a lot of planning, and like been getting a lot of things geared up, things coming in, etc. in relation to this nameless project- not really important anyway, more just the general sentiment- and i just found out that this item had already been sent i guess, but got returned, tho I've been watching the mail like crazy and all my info is totally correct on their end, so its a total unexplainable bummer lol.  These things happen.  It's just a disappointment timing wise, i'd had a feeling it'd be coming in any day now so was excited lol.  It'll work out.  Actually, the person I'm dealing with, despite what I've been hearing from ALL OVER THE PLACE lol, has actually been really good- responding to me very fast and being really helpful with info etc.  I honestly think the problem is with my mail people and neighbours- i need to rent a p.o. box for my saber stuff lol!     

I have to say, Jed's graflex project couldn't have had better timing :).  It definitely brought a much needed smile to my face before i crash n get ready for work tonight lol.  And actually its hilarious, because he got that for his b day, and i had actually considered this thing i mentioned as a sort of early b day thing for me too.

i've been really swamped with work and a bunch of other projects/ plans n whatnot- but i have managed to progress on my sentinel :).  I finally found the hidden mother load of dead fluorescent tubes at work... i KNEW it was there somewhere lol.  Grabbed two on the way out this morning.  One thing you might notice if you ever go electrical pin hunting- the size and quality of the pins will really vary across diff tubes.  I just eyeballed what i thought would be the right size... and hit the nail on the head 8). 
(http://i736.photobucket.com/albums/xx2/major_major/856600D2-2A9C-49F5-9FDA-0C391693A904_zpsonyaqerh.jpg) (http://s736.photobucket.com/user/major_major/media/856600D2-2A9C-49F5-9FDA-0C391693A904_zpsonyaqerh.jpg.html)             

Just a quick word on this... obviously everyone knows to be super careful when working with tools etc, even seemingly simple stuff like pliers n hammers n whatnot- but thats always when the stupid injuries happen is with the easy stuff so its worth being extra cautious.  you REALLY do need to be careful doing this, for a million reasons.  The tubes are pressurized so they'll really blow sometimes, and they're just absolutely full of disgusting, terrible things you don't want on/ in you.  Be super careful WHERE you do this, powdered glass and chemicals n whatnot should never be anywhere your pets or kids go, ever, period.  Yada yada... ok.

(http://i736.photobucket.com/albums/xx2/major_major/67657F18-A1A3-4C46-8BC8-016BDC40D563_zpsnfawyvar.jpg) (http://s736.photobucket.com/user/major_major/media/67657F18-A1A3-4C46-8BC8-016BDC40D563_zpsnfawyvar.jpg.html)
and for scale:
(http://i736.photobucket.com/albums/xx2/major_major/412ED71E-FB42-4586-B754-F6E92E00466F_zpsa71zvpdx.jpg) (http://s736.photobucket.com/user/major_major/media/412ED71E-FB42-4586-B754-F6E92E00466F_zpsa71zvpdx.jpg.html)
The pins themselves were mounted in a sweet synthetic particle/ composite board, basically like a circuit card- so i've kept a couple mounted in case i end up making use of that in this or other projects :). 
Gonna get back on this like crazy this weekend- keep you posted, MTFBWY.
(http://i736.photobucket.com/albums/xx2/major_major/4171FC50-7CF4-4A2C-AFF8-7F485C93D36F_zpspk4jnvjk.jpg) (http://s736.photobucket.com/user/major_major/media/4171FC50-7CF4-4A2C-AFF8-7F485C93D36F_zpspk4jnvjk.jpg.html)

Rev, if I wanted to use pins of a fluorescent tube, could I just shatter the light outside to lower my overall risk? I'm clumsy and I would hate to get the pressure crap on me.

yyyyep :).  Think that's the easiest/ fastest way by far... not to mention funnest!  Feels like you're in the movie office space lol.  If you're worried about the area you're doing it in might be sensitive to glass lying around (i mean you can just sweep up, but say if its like a driveway or something and you wanna be sure) you can always slip a garbage bag over one end, and then tap that end with a hammer- it'll contain all the mess, then you just carefully fish out the end cap, and tap it a bit more with the hammer- there will be a bit of glass and gross junk stuck right up inside to the end cap, but even just light tapping will shake/ break that off.  Just break away the layers of vacuum tubes that house the filaments right in the end cap, and take any kind of cutters/ pliers and there will just be two little filaments/ wires to snip, they actually go right into the electrical pins from behind- then you can yank those puppies out.  Its super easy don't let my long winded description fool you :).   

Thanks for the info, I can't wait to see your finished activation box.

Test fitting- Still have to dress up the plastic casing/ port where the wire comes in a little, but only main thing left on this box is to add the trimmed circuit card piece on the top. 

The teaser shot lol...
(http://i736.photobucket.com/albums/xx2/major_major/854424EC-BCE8-4D7C-80A7-AD9743ADC670_zpszxdk3gj4.jpg) (http://s736.photobucket.com/user/major_major/media/854424EC-BCE8-4D7C-80A7-AD9743ADC670_zpszxdk3gj4.jpg.html)

Ok, ok, there they are lol.
(http://i736.photobucket.com/albums/xx2/major_major/C3E7B999-B9AB-4529-BC90-E64C2D8D7B99_zpsmtm6zase.jpg) (http://s736.photobucket.com/user/major_major/media/C3E7B999-B9AB-4529-BC90-E64C2D8D7B99_zpsmtm6zase.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/41F8AB03-31F5-4684-95A9-F9D0F9679A70_zpsvhqe1rem.jpg) (http://s736.photobucket.com/user/major_major/media/41F8AB03-31F5-4684-95A9-F9D0F9679A70_zpsvhqe1rem.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/B345D929-B370-4A2B-81B1-91FB2940A30A_zpsbqhetha9.jpg) (http://s736.photobucket.com/user/major_major/media/B345D929-B370-4A2B-81B1-91FB2940A30A_zpsbqhetha9.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/D3E2EF3D-B727-4F5D-A50D-BCE1432E79B4_zpsf17ecbe5.jpg) (http://s736.photobucket.com/user/major_major/media/D3E2EF3D-B727-4F5D-A50D-BCE1432E79B4_zpsf17ecbe5.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/80A71862-329D-4FA7-A536-F53EF56B90D8_zpsyvihh74y.jpg) (http://s736.photobucket.com/user/major_major/media/80A71862-329D-4FA7-A536-F53EF56B90D8_zpsyvihh74y.jpg.html)

So, about the card.  It'll sit on the top surface of the box/ base piece, with the aluminum piece, wire, and gold solder pad bunny ears thingy all sitting on top of the card.  It's gonna look sweet:
(http://i736.photobucket.com/albums/xx2/major_major/DC265BA0-F3F3-4AAE-A016-307B28069A6D_zpsqapgewvv.jpg) (http://s736.photobucket.com/user/major_major/media/DC265BA0-F3F3-4AAE-A016-307B28069A6D_zpsqapgewvv.jpg.html)
Now, I'm on the fence about which card I'm gonna go with ATM- i got a few variations on me already... But they're SO dear to my heart, these ones, that I'm not sure I'll be able to hack one up lol.  These might just get saved for something SUPER special... Though I DO love them so much so it'd be cool to have one on my dueler, would look amazing!! 
(http://i736.photobucket.com/albums/xx2/major_major/F47DC61C-3CD9-43A8-BCCD-85B217EE3106_zpszua4evax.jpg) (http://s736.photobucket.com/user/major_major/media/F47DC61C-3CD9-43A8-BCCD-85B217EE3106_zpszua4evax.jpg.html)
I can't decide if I should use, and on top of that I'm not sure which I'd use in that case- I'm gonna trim the card so that I can preserve the general look of it (since my box is narrower, the image/ plating would get cut off in odd way when I fit it to the top surface of the box- but if I strategically trim out a swath down the middle and capture the right cropping / proportion of silver trace and gold it'll just basically look like a tiny little narrow version of the same image).  Well basic idea anyway, I'll just make it look right for the size/ shape.  I've got a few more types of circuit card on their way, so I'm gonna wait to make the call till I can check those too.  One in particular I'm holding out hope for, cause it's also really high quality like this, with gold plating and whatnot, only it's cheaper and I've got more of it lol.  We'll see- keep you posted.  MTFBWY.

Hey Rev.  You lost me on this customization a long time ago but it does look quite intriguing.  +1 for your efforts and ideas so far.   :D

More progress on the saber- sorry it's been so slow!  I've got a ton going on behind the scenes right now with parts n stuff coming in etc, but i'm still plugging away.

I decided to go with a completely different circuit card just because it suited the piece best IMO- cut and sanded it to shape with a dremel, thin cutting disk, and drum sanding bit (used tape to protect top surface).  It'll get tweaked just a tiny bit when i fit and secure everything for the last time, but i gotta wait to do that until i mount it on the body, because i'll likely take a torch to the base once I've screwed it down, and draw a bead of metal working solder around the join of the base and hilt to seal the crevice and give it that welded look.  then i'll be able to attach everything for the last time and give the final touches.  I should have the engraving done soon too so i'll keep you posted :).  It's tedious work using the scriber to go back over the stuff i did with the electric engraver, but it's definitely worth it.
(http://i736.photobucket.com/albums/xx2/major_major/5DE63F32-0F41-4670-A7F8-8C73E8CDCE6B_zpsharmqofg.jpg) (http://s736.photobucket.com/user/major_major/media/5DE63F32-0F41-4670-A7F8-8C73E8CDCE6B_zpsharmqofg.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/86E08A40-ECA8-49E7-A173-2390703D0AA3_zpsq5tpznyr.jpg) (http://s736.photobucket.com/user/major_major/media/86E08A40-ECA8-49E7-A173-2390703D0AA3_zpsq5tpznyr.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/0DCEE7CE-1679-48B7-A937-B2FD343C80C1_zpsannel228.jpg) (http://s736.photobucket.com/user/major_major/media/0DCEE7CE-1679-48B7-A937-B2FD343C80C1_zpsannel228.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/36D1356C-EDAC-428B-9261-7ABF6A037247_zpsvamtje0o.jpg) (http://s736.photobucket.com/user/major_major/media/36D1356C-EDAC-428B-9261-7ABF6A037247_zpsvamtje0o.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/233DFF30-F261-469C-8ECB-D0C24DD8CFAA_zpslgucghle.jpg) (http://s736.photobucket.com/user/major_major/media/233DFF30-F261-469C-8ECB-D0C24DD8CFAA_zpslgucghle.jpg.html)

MTFBWY :).

Wow, I'm really late to this party  :o

This looks like some awesome work you have going on for this saber. So many tiny pieces coming together on this saber.

I remember when I was younger, I tried to build a toy lightsaber that looked more like the ones from the movies, rather than those plastic ones with the telescoping blade. I took a styrofoam rod and cut it to length, covered it with some contact paper, and cut a piece off the top as a base. Then I found this old camera in the house (a cheap one mind you) that wasn't used anymore and broke it apart and started using pieces of it on the saber, with a pommel made out of a hose cap and a marble (of all things). I even tried to find a colored tube to put on the end, but never found anything that worked like I wanted it to.

Anyway, I'll definitely be keeping up with this project. I can only imagine how many things you must be working on  ;)

Awesome thread! Very nice work, it adds a whole lot to the default hilt!

Thanks guys!  Yeah Sedsti, I totally know what you mean- it made me feel like a kid again digging thru the found parts and getting all excited lol :).  Lol, and yeah, I've got just a TON on the go ATM ;), sooo much saber stuff to do... I wouldn't have it any other way lol.

That circuit card really makes the activation box pop! Can't wait to see what else you've got planned!

Thanks Greg!  I can't wait to get into the rest of this hilt, I've got some really cool stuff in the works for it :).  Keep you posted, MTFBWY.

Once again amazing work. Can't wait to see how this one develops.

Thanks Hansrad!  Really appreciate :).  You guys keep me so motivated, I can't thank you enough for the encouragement and for taking the time to pop in and see what I'm up to.  I'm always so driven, excited to pop on the forum and share my progress with everyone and listen to their input- there's so much inspiration here on the forum, it's insane.  Keep you posted, MTFBWY.

Kewl, its starting to come together, Best part about imagination is seeing it unfold in the physical world :D

So, when i attach the box to the grip section of the saber... I DON'T want it to look like this lol:(http://i736.photobucket.com/albums/xx2/major_major/0E9F42A9-D1A6-40CF-B9AB-0901709BD873_zpskhmjwqjk.jpg) (http://s736.photobucket.com/user/major_major/media/0E9F42A9-D1A6-40CF-B9AB-0901709BD873_zpskhmjwqjk.jpg.html)
I guess you could call that the 'before' shot.

To avoid that, all you need are the lungs, and stones lol, of a free diver hahah!! No but seriously, i don't think i dared take one breath the whole time i worked at this lol.  The grip section here is the one place on this whole hilt where the metal is pretty thin actually.  Clenched jaw, white knuckled was an understatement lol.  I had to cut down through the ridges but not take anything deeper than the bottom of the grooves to preserve the precious little metal wall of the hilt in this section so that there'd be enough left for good threads when i tapped it.  To be honest, as i touched the cutting disk to the hilt here for the first time, i wasn't sure i could pull this off lol!  (mostly just used the disk believe it or not- tiny bit of grinding at very end)  But i'm surprised, it actually achieved a really good fit :).
(http://i736.photobucket.com/albums/xx2/major_major/4CBCC5A4-AE02-49DB-80CE-20506D017D91_zpszklnhrga.jpg) (http://s736.photobucket.com/user/major_major/media/4CBCC5A4-AE02-49DB-80CE-20506D017D91_zpszklnhrga.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/B4295F3A-2ACD-4C9E-99A8-FDF640882C32_zpsx5noz7bc.jpg) (http://s736.photobucket.com/user/major_major/media/B4295F3A-2ACD-4C9E-99A8-FDF640882C32_zpsx5noz7bc.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/4A2DCED9-6E61-4B0B-8CAE-969113C9CD59_zpsluyx4vbw.jpg) (http://s736.photobucket.com/user/major_major/media/4A2DCED9-6E61-4B0B-8CAE-969113C9CD59_zpsluyx4vbw.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/B2F8C319-88D1-4F69-BDF3-33FEED953B9B_zpsb9yujafd.jpg) (http://s736.photobucket.com/user/major_major/media/B2F8C319-88D1-4F69-BDF3-33FEED953B9B_zpsb9yujafd.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/C62CD8EF-DFF4-4254-8B6E-C77ECED5E7E0_zps2fve14b5.jpg) (http://s736.photobucket.com/user/major_major/media/C62CD8EF-DFF4-4254-8B6E-C77ECED5E7E0_zps2fve14b5.jpg.html)

Now, I've always been the first to admit i'm a newb when comes to electronics lol... but i'm pretty sure these little guys aren't ideal lol ;).
(http://i736.photobucket.com/albums/xx2/major_major/69E5B35E-1980-4AB5-8FD3-566DC1F046F3_zpsw4sstaj2.jpg) (http://s736.photobucket.com/user/major_major/media/69E5B35E-1980-4AB5-8FD3-566DC1F046F3_zpsw4sstaj2.jpg.html)

Easy fix.  See the sharpie marks right at where the threads stick into the inside of the body?  I just marked the spot- now its as easy as just slapping a couple nuts on the screws and hacking the threads off, then when you unscrew the nuts they'll clean up/ restore the mangled thread back to usable- works every time :). 

Also, one thing i always do whenever possible, though some would call it cheating i guess lol.
(http://i736.photobucket.com/albums/xx2/major_major/453FF836-9CB2-43ED-8572-0B783F9D609B_zpszdby2zis.jpg) (http://s736.photobucket.com/user/major_major/media/453FF836-9CB2-43ED-8572-0B783F9D609B_zpszdby2zis.jpg.html)
I actually used the box piece to ensure everything aligned.  I did the same thing to tap.  I actually held the tapping wrench right in the recessed holes in the box and tapped right down through so it was easy to see how straight i was.  Sounds stupid, but even the slightest bit of an angle to that tap and my screw heads wouldn't have fit right inside the recesses. 

I'm likely still going to take the torch to this and put some metal (not electronics) solder down around the join- either that or powder coat the gouged area black just for that extra touch so the box looks extra tight in the grips.  Keep you posted, MTFBWY :).

Excellent finesse. On the flush fit good work

Thanks Bulvoy!  Sorry I somehow missed your first comment- I totally agree, there's nothing quite like the feeling of dreaming something up and then seeing it come into reality.  Thanks for coming along on the journey :).

Holy cow I can't imagine the guts it took to do that to your saber. That's awesome. I agree with you and Bulvoy that seeing something from your head transform into something in your hand is amazing. The most important thing is having the perseverance to get through any bumps in the road that pop up along the way. And lots and lots of patience ( that's the part that gets me a lot of the time).

Another +1 Rev . . . enjoying the journey  ;)

A question . . . have you ever looked into a milling vice and milling cutter to use with your drill press ? . . . could be handy for small projects like this ?  :)

Thanks Jed! 

Ummm... just a question back at you lol, are you telepathic or something ;) ?  I've been looking around, in decision mode for about a month or so now lol.  Ive even been looking around at these companies out there that take old industrial/ commercial equipment and refurbish it- a lot of businesses buy major pieces of equipment this way because costs are so high- like some of these machines are still multi million dollar purchases 20 years later on the used market.  I intitially set about finding out what a run down CNC machine would set a guy back.  Turns out in some places in Canada you can own a decent sized home on a good chunk of land for about the same price lol- now I don't think my landlord would be cool with me moving it into the apartment, and any way I don't think it'd fit up our stairs lol (it'd probably collapse my dillapidated floor lol) so I think I better go with the house first!  But there are lathes and milling and axis stations that turn up here and there in decent shape for more realistic, though still pretty huge, prices.  It sounds nutty, but it'd basically just be like buying a car, something so common place for the average person in first world counties these days that it's mundane, just taken for granted. 

These really are big decisions so who knows, they're so long term they're just pipe dreams for now I guess... But how cool would it be to only ever order parts because a piece caught your eye, never because you needed it.  You'd never really be in need of an emitter, pommel, etc. when you can just hunker down on a weekend with some stock and make one  8).

Wow, don't know why I haven't looked at this thread before. Awesome work so far!

Can't wait to see the finished results!

Thanks so much everyone!  It's easy to do Venthros, there's just so much great stuff on the forum, it's hard to catch them all right away- I'm always finding threads i missed.  Yeah i was PRETTY nervous not gonna lie, Hansrad lol.  I just went really slow, and cut in really short bursts to not loose focus on the very cutting edge of the disk and grinding stone, you're staring so intensely in on EXACTLY where the edge of the disk will touch metal and holding you're breath.  But as you start to see the shape emerge and you start to achieve a fit you realize you're gonna be able to pull it off lol, and its so rewarding! 

So this piece is almost a wrap :).  It's all permanently secured/ assembled etc.  I just have to dress up the little port where the wire exits still to match it with the overall look of the box a bit more- also this isn't how the wire will actually run, its just to give you the basic idea of the look:(http://i736.photobucket.com/albums/xx2/major_major/5FDC0224-3374-4252-9355-1E775D3A68EA_zpskfc6kt4g.jpg) (http://s736.photobucket.com/user/major_major/media/5FDC0224-3374-4252-9355-1E775D3A68EA_zpskfc6kt4g.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/BF6684A8-E4CD-40A7-8B09-C1DC4119FBB2_zps0aex72kz.jpg) (http://s736.photobucket.com/user/major_major/media/BF6684A8-E4CD-40A7-8B09-C1DC4119FBB2_zps0aex72kz.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/B33C3F41-175D-4939-AF90-1653EC8247B7_zpsr8taqvsg.jpg) (http://s736.photobucket.com/user/major_major/media/B33C3F41-175D-4939-AF90-1653EC8247B7_zpsr8taqvsg.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/13313A1C-ED33-4DDD-AE06-096949840589_zpsslo7fx8c.jpg) (http://s736.photobucket.com/user/major_major/media/13313A1C-ED33-4DDD-AE06-096949840589_zpsslo7fx8c.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/A2D87C70-DAB8-48B0-B79F-984CEAB31653_zpsnzhjafoh.jpg) (http://s736.photobucket.com/user/major_major/media/A2D87C70-DAB8-48B0-B79F-984CEAB31653_zpsnzhjafoh.jpg.html)
I actually soldered some of the components in because it looked cooler, and helped secure them better.

I'm relocating the latching switch- so in its place i'm making a sort of bezel to allow for the mounting of an accent led:
(http://i736.photobucket.com/albums/xx2/major_major/50181C27-95AB-4F3C-9C5F-E86ED034F1C4_zpsnhgfiirj.jpg) (http://s736.photobucket.com/user/major_major/media/50181C27-95AB-4F3C-9C5F-E86ED034F1C4_zpsnhgfiirj.jpg.html)
(side note, only the very bottom line of aurebesh here has been retouched with the scriber- only made one pass on that line and it made a noticeable diff, so I'm feeling good about the way the engraving will turn out once I've gone over it all many times)
I could use your guys' opinions on this one... I'm kinda torn as to which style accent to go with:
(http://i736.photobucket.com/albums/xx2/major_major/8ED0DB73-90C5-4107-9D98-6CC0C549FF70_zpsx1q7dto9.jpg) (http://s736.photobucket.com/user/major_major/media/8ED0DB73-90C5-4107-9D98-6CC0C549FF70_zpsx1q7dto9.jpg.html)
This one has a narrower, tiny protruding bezel type look, like a micro version of a graflex red button almost.  I like the bezel and how much of the die is exposed on it.  this is the one lying on the cloth in the first pic for ref of size of profile/ protrusion.

This next one is more low pro, which i like, tho its housing is wider and less of the die shows:
(http://i736.photobucket.com/albums/xx2/major_major/6B0BB2D2-5410-43A2-B1E5-78A87CD1CE1F_zpsdgkevvqa.jpg) (http://s736.photobucket.com/user/major_major/media/6B0BB2D2-5410-43A2-B1E5-78A87CD1CE1F_zpsdgkevvqa.jpg.html)
What do you guys think?  I should point out both will sit down in the bezel a lot better, i just threw them in quick for ref pic- the back nut is still sitting on both in these shots causing them to sit higher up and uneven.  Also, the brass bezel itself has more to it than that washer, I just have some of it tied up in progress atm.

Ok, so- the plans for this project are still up in the air for a couple reasons.  I want to swap the battery pack for a power bank i have on the way atm- but i'm not knowledgeable about electronics enough yet to know if the 5V output of the bank will be enough for the resistored red led AND the accent led.  If not i may have to just stick with the rechargeable batteries I've got now, which would kind of be a bummer.  If the bank's a viable power solution, i have to figure out if my resistor value changes- but other than that i'd be good, i've got some variable resistors incoming for the accent. 

But even IF the bank can power it, my plans are still up in the air due to space inside the hilt.  Ideally, i'd put the latching switch down in the centre of the pommel- but, with the connections sticking straight up into the area that typically contains the power source, i imagine it'll be a miracle to fit the power bank in behind it.  The choke would be the first obstacle, though its thick enough to bore out more.  But the next roadblock would be the pins/ connections to the accent led sticking down from the old switch location.  I'd essentially have to pray the bank fits between the connections of the switch and the accent.  If i could get it to, i'd run the usb out to a recharge port to eliminate ever having to remove the bank:
(http://i736.photobucket.com/albums/xx2/major_major/E6F5FE96-68BE-4287-8E7B-E8922050A239_zps8x8qidgn.jpg) (http://s736.photobucket.com/user/major_major/media/E6F5FE96-68BE-4287-8E7B-E8922050A239_zps8x8qidgn.jpg.html)

If the bank can't be made to fit, I'd just put the switch on the back of the hilt somewhere, in the choke if it'll fit depth wise, tho i suspect not so probably down low on the back of the main body section.  In that case I'd run the recharge port out the bottom of the pommel, tho it wouldn't be as big of a deal since the bank would be easily accessible with that set up:(http://i736.photobucket.com/albums/xx2/major_major/07D40C7B-2770-402D-AEDA-FBA5874355E8_zpsmmtubgfs.jpg) (http://s736.photobucket.com/user/major_major/media/07D40C7B-2770-402D-AEDA-FBA5874355E8_zpsmmtubgfs.jpg.html)

If for some reason the power bank can't power the accent AND the main led, there would be one huge silver lining :).  I know for a fact i can easily fit the existing AAA battery pack in the hilt with the switch in the pommel set up i'd prefer!  So no matter how you slice it, this is gonna be a fun, cool little mod for my current main dueling saber :).  O!!  Which seem like just about as good a segue as there is to another thing i was considering lol.  The name... what do you guys think about something like the Splicer, or Sith Splicer etc. to go along with the crazy, splicer, patchwork, alchemy type look this things gonna rock?

Apologies for those two-second diagrams lol!  Keep you posted, MTFBWY- and i'd love to hear your preferences on the accent :). 

Nice, Rev! It's coming together! The box you added looks great  :)

I prefer the second, sloped accent LED. I think it fits better with the design of the saber you have.

I'm gonna go ahead and say you're right that the normal latching switch won't fit into the choke point, but you may be able to fit a simpler one in there if you really wanted.

I agree that the second led option seems to fit better. As always looking this looking amazing.

Thanks guys!  Appreciate the input and encouragement :).  Ya I'm leaning that way too.  One big factor is everything so far has followed a form follows function principle- despite what it might look like, I've been making sure to stay true to the dueling saber function- grip, etc been deciding factors of placement of things.  That's actually the whole reason I wanted to move the switch.  Though I usually grip up higher (I take pretty wide grip like katana), I wanted to go extra mile and get it right outta the way.  The second accent is by far the most low pro, best gripping. 

Got the power bank in today :).  Originally it was just going to be burried inside the hilt (obviously lol) but now that I'm holding it, my wheels are whirling involuntarily lol!  I'm surprisingly thrilled with it, not that I expected it to be terrible or anything lol! but I've always just thought about it as a practicality... Like I mean, what excited me about the bank was the functionality of it/ incorporating it into build- but I didn't expect to be inspired to make it contribute greatly to the overall look of the project.

  I must not have looked at the pics of it closely when I ordered it (was more concerned about dimensions and specs) - surprised to see that it has this huge/ and surprisingly bright status indication led cleverly located in the word 'power' on its front face. 

Don't worry, not breaking the add rule- that's not the brand/ company name- evidently the creative juices just weren't flowing the day they had to decide what to have printed in bold letters across the product lol!  Or like maybe the big boss was just hungry at that meeting lol: "Hmmm... 'Power Bank'... I like that Johnson, let's go with that.  Lunch time people."  Lol.

(http://i736.photobucket.com/albums/xx2/major_major/69526660-D53B-4887-9E1C-8D28E795D325_zps630ycehq.jpg) (http://s736.photobucket.com/user/major_major/media/69526660-D53B-4887-9E1C-8D28E795D325_zps630ycehq.jpg.html)
The light glows bright sky blue when discharging power to device, and a deep red when charging.  The charging pic was taken under some industrial lighting, so I tried to block it out with my sweater so you could see brightness. 
(http://i736.photobucket.com/albums/xx2/major_major/91A167E2-52B6-47A2-90AB-D972EAB59435_zpsnva92pqt.jpg) (http://s736.photobucket.com/user/major_major/media/91A167E2-52B6-47A2-90AB-D972EAB59435_zpsnva92pqt.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/C1765C09-0652-4216-B2DE-B603524B9418_zps1kyexbjy.jpg) (http://s736.photobucket.com/user/major_major/media/C1765C09-0652-4216-B2DE-B603524B9418_zps1kyexbjy.jpg.html)

So the new game plan is to secure the bank in exact/ permanent place via tapping and black set screws and spacers mounted inside hilt, and cut or drill a window into the hilt to allow a mini cross section type view of a tiny bit of the battery bank (where the light is) gaining an extra 'freebie' accent led of sorts- when my sabers on it'll shine bright blue, when it's charging, a deep red.  Really excited about this- combined with the legit red accent I'm mounting in the old switch location it's gonna look sweet!  it'll really go well with the look of this crazy sith splicer saber to have another blue/red light peeking out down there, and the look inside to the actual power source jives with the mad science project too :).  Keep you posted- just waiting on a small truckload of variable resistors of diff mA values which will be in any day now, then I'll have everything I need to finish! 

I'll ding the rest of the engraving off in the meantime while i wait for the last components- prob be done this weekend, then it's on to the wiring.  I've got another small detail to make for the body, but I'm holding off until I know 100% where I'm putting the switch, in order to get the best placement. 

Will have some new progress pics up soon- MTFBWY :). 

Im liking this idea, a little extra Umhfff. i musta missed the post originally on the switch. I vote for the more exposed bezel ,

Good thinking Rev. Point to you!

Nice freehand engraving! Very creative design, thanks for sharing.

Thanks everyone! 

Thanks blackrock, I've only gone back over some of the engraving with a scribe- the rest is just roughed in with an electric engraver.  I'm really happy with how the combo of electric and manual engraving tools is turning out, once I've touched it all up it'll look really nice :). 

Thanks for the input Bulvoy- I'm really torn, so good to hear everyone's opinions :).  There's things I really like about both accents.  Can't wait to be able to cut one in!  I got everything all ready n waiting for that now, so will be pretty quick/ easy once resistors arrive:
(http://i736.photobucket.com/albums/xx2/major_major/6D6DCE0D-046D-4892-9863-FDA7C0C75420_zpsmm2wqjmq.jpg) (http://s736.photobucket.com/user/major_major/media/6D6DCE0D-046D-4892-9863-FDA7C0C75420_zpsmm2wqjmq.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/AD3E1E76-1FD0-486C-AF0D-42AE2FCFBB1F_zpsb1ctxq6v.jpg) (http://s736.photobucket.com/user/major_major/media/AD3E1E76-1FD0-486C-AF0D-42AE2FCFBB1F_zpsb1ctxq6v.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/7C9371B7-D9BD-4279-B733-F922BE2E8F82_zpsosgmzb8b.jpg) (http://s736.photobucket.com/user/major_major/media/7C9371B7-D9BD-4279-B733-F922BE2E8F82_zpsosgmzb8b.jpg.html)
Was every bit as easy as CJ Nihilus said it was when he showed how to do it in his thread about 'the best battery set up for stunts'.  You simply cut the back off the end of a usb cable to access the pins and solder the leads in place and its in the bag:
(http://i736.photobucket.com/albums/xx2/major_major/447DFBBB-FD21-42D7-A3F4-3C6D64E5AB1B_zpsds6ltlro.jpg) (http://s736.photobucket.com/user/major_major/media/447DFBBB-FD21-42D7-A3F4-3C6D64E5AB1B_zpsds6ltlro.jpg.html)
Lol
Keep you posted, MTFBWY :).

I prefer the 2nd tapered LED the best. It just feels more realistic to me. This rig is really turning out top notch. Keep it up!

This entire thread is customLishious  if that's  such a word lol. Very interesting starting from the beginning reading this

Thanks everyone!  Appreciate the encouragement and input :).  Darth Arlo (my dog lol) is sick atm, so I didn't get much time for the project this long weekend :(.  But I did manage to get a good start on installing the power bank- really happy with how it's turning out:
(http://i736.photobucket.com/albums/xx2/major_major/F57CE745-3A24-4B23-B668-1FCC2275BEE2_zpsvbzgyc8h.jpg) (http://s736.photobucket.com/user/major_major/media/F57CE745-3A24-4B23-B668-1FCC2275BEE2_zpsvbzgyc8h.jpg.html)
The best way I know how to make nice shaped elongated windows or grooves without a milling station.  Just drill holes for your ends and then cut out the area in between with a dremel and disk, then touch it up with grinding stones etc.  I lost concentration a couple times over arlo (my fault not his lol) and made a couple little scratches, but thankfully they're super shallow so I'll be able to hide them with blackener.
(http://i736.photobucket.com/albums/xx2/major_major/BB2017CF-B415-46D2-A884-0FE008D268E5_zpsqi9ocz5u.jpg) (http://s736.photobucket.com/user/major_major/media/BB2017CF-B415-46D2-A884-0FE008D268E5_zpsqi9ocz5u.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/9A9D6065-152A-4BC3-9C03-24CA6B1E615C_zps50akqctp.jpg) (http://s736.photobucket.com/user/major_major/media/9A9D6065-152A-4BC3-9C03-24CA6B1E615C_zps50akqctp.jpg.html)
I forgot to take a pic of the bank all dressed up, outside of the hilt- I meant to.  No biggie I still have a bunch left to do on this part so I'll get that soon.  It's pretty neat- it won't really translate in pics, but I put a bunch of copper wire and details around the edges of the bank, so that in person when you look at angles down into the window you see really believable depth/ details if you know what I mean. 
(http://i736.photobucket.com/albums/xx2/major_major/690A3B7C-4F09-4168-B68F-F96DC47F39FD_zpsr3nflg0s.jpg) (http://s736.photobucket.com/user/major_major/media/690A3B7C-4F09-4168-B68F-F96DC47F39FD_zpsr3nflg0s.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/68209E5D-E3B4-4D31-84C6-4428A80585B7_zps4laikvdw.jpg) (http://s736.photobucket.com/user/major_major/media/68209E5D-E3B4-4D31-84C6-4428A80585B7_zps4laikvdw.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/AF026AB7-BEB4-4C0F-8E8B-2F34DB05F47F_zpstl9smepn.jpg) (http://s736.photobucket.com/user/major_major/media/AF026AB7-BEB4-4C0F-8E8B-2F34DB05F47F_zpstl9smepn.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/2B0FBCDD-3A0F-4A13-A588-7A055F9FDA7E_zpsx7nskyo2.jpg) (http://s736.photobucket.com/user/major_major/media/2B0FBCDD-3A0F-4A13-A588-7A055F9FDA7E_zpsx7nskyo2.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/FDF0A2B5-E4D9-4D14-8CCC-8A42455D02AA_zpsj5ikheat.jpg) (http://s736.photobucket.com/user/major_major/media/FDF0A2B5-E4D9-4D14-8CCC-8A42455D02AA_zpsj5ikheat.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/635DD696-97D6-4E1F-9EC7-0B1EC5FEE743_zpsl8zyuu8j.jpg) (http://s736.photobucket.com/user/major_major/media/635DD696-97D6-4E1F-9EC7-0B1EC5FEE743_zpsl8zyuu8j.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/71185304-FE19-4C0E-A197-3884FC58EB12_zpsx9hi5969.jpg) (http://s736.photobucket.com/user/major_major/media/71185304-FE19-4C0E-A197-3884FC58EB12_zpsx9hi5969.jpg.html)
It was surprisingly easy to do :).  I just drilled the matching hole in a piece of circuit card, lined it up and super glued it to the tops face of the power bank.  Then that gave me the perfect base to attach everything to, since I could solder everything right onto the card/ plating.  I just tossed the bank in quickly and stuffed the wiring through the emitter for the sake of hooking up for photo- still have a ton to do before I install everything permanently.  Keep you posted, MTFBWY :).

This just keeps getting better and better.

So then, no activation box?

O no worries Greg, that box isn't going anywhere lol!  I'm quite fond of it :).  This is on the exact opposite side of the saber as the activation box.  It's pretty much the same size and shape as the base of the act box, more or less located in same area of grip section, and they both have that circuit card pattern so there's a sort of symmetry to the grip section now... Maybe symmetry not right word, but it looks nice and balanced now :).  At work ATM so can't throw up a pic, but I will in morning when get home for sure- I'll still be working on these pieces some more anyway.  The wire that runs outta the act box will end up going down into this window.

O and thanks Hansrad!  Appreciate :).
Keep you posted :).

Revan My Friend, you are doing such a great job on this hilt, wow man, it looks amazing!!! The Force is definitely Strong with you!!
Point for you!! :)

Fitting in nicely . And agreed on the outer box it's a keeper.if not we'll have to remove some of your pts. Lol. Seriously though alot times the best mod ideas are discovered on the fly as you start with the original plan, and of course the " Oh wait lets try this " kicks in.. hehe.
           I understand with project time. Real life gets in the way. Finally got the ideas i want laid out and some time to start the  Menace Project this week keep an eye out.

Good stuff Rev, another point  :) . . . . I've been meaning to chime in on your last questions, lol, some time soon . . . but have a new question for you, how'd you go with the latching switch ?

Thanks a million guys!!  Really appreciate everyone's encouragement :).  Will do, Bulvoy- look forward to seeing!!  Hey Jed, well, I'm not 100% on the switch yet- but it's looking like the choke won't be an option for location- I seriously think I could have bent/ rigged the pins of the switch to fit if it wasn't for the USB adapter and wiring from the bank sticking up into the choke area.  I don't think I could get the switch connections bent far enough apart to allow the wiring/ USB plug to clear through/ between them, if you can picture?  They'd likely break- bit too much of bend required. 

But things are looking hopefull IMO, we'll see how plays out.  I haven't had a ton of time to play with, but the regular sentinel solid pommel is quite deep- looks like I could fit almost 2/3 of the switch inside it- it could easily be bored/ drilled to house the switch.  The little bit of the switch and connections that would end up sticking out past the back of the pommel into the area of the power bank JUST might fit.  The bank takes up MOST of the room in the grips, but there is a tiny, tiny bit left over.  If I end up needing a little more room for the pommel switch location it wouldn't be much- so I could either just make a little bezel for the switch which gives me that extra little bit of clearance- or, what I'm leaning towards ATM, pick up a little 1/2" or 3/4" mhs extension.  Then I'd have tons of room to mount the switch in pommel.   Even before I considered moving the switch to pommel I wondered about extension, since I take a pretty wide grip, so I'm thinking that might be best, not to mention one of the easiest, solutions?  Of course, as Sedsti suggested, I could always just grab another, smaller latching switch too :). 

Added a tiny bit more detail to circuit card in cut away this morning- gold solder tab, to which I soldered a little gold capped/ plug, pcb type wire:
(http://i736.photobucket.com/albums/xx2/major_major/F1603344-0507-4F30-A847-38CC6D697503_zpsa9qybiz7.jpg) (http://s736.photobucket.com/user/major_major/media/F1603344-0507-4F30-A847-38CC6D697503_zpsa9qybiz7.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/BBA1A694-B0C9-4766-A149-032E26E180E4_zpsrg0i47dc.jpg) (http://s736.photobucket.com/user/major_major/media/BBA1A694-B0C9-4766-A149-032E26E180E4_zpsrg0i47dc.jpg.html)

Here's that view I promised for Greg, so can see relative positions of box and cut away:
(http://i736.photobucket.com/albums/xx2/major_major/484DA8A7-BBAB-4F10-A8D2-A83FB0E4CEFB_zpseczordu3.jpg) (http://s736.photobucket.com/user/major_major/media/484DA8A7-BBAB-4F10-A8D2-A83FB0E4CEFB_zpseczordu3.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/F9130C21-DCE9-49B9-B8F2-F740016F4EAF_zpsgciifrst.jpg) (http://s736.photobucket.com/user/major_major/media/F9130C21-DCE9-49B9-B8F2-F740016F4EAF_zpsgciifrst.jpg.html)
If you look close, in both pics you can just start to see some of the copper wire around the edges of bank.
Keep you posted- and I'm really looking forward to seeing your guys latest projects/ updates!!

Simply amazing!

Thanks Greg :).  Jed got me ta think'n about the switch location more, and from a few simple decisions that had to be made in regards to that, I pretty much arrived at my entire wiring setup lol :).  So thanks Jed! 

I'm really excited about this- gonna be a blast to do, and there's gonna be a few twists n turns along this path to completion!  Here's the basics though I'm gonna save some of the exact details as surprises for along the way.

Sorry about the rough drawings- I don't actually know how to do proper diagrams lol, and plus after brainstorming all day this came to me while I was at work so I scribbled it down lol.
(http://i736.photobucket.com/albums/xx2/major_major/D685E818-B320-4128-BE0B-FBEA0684EB3D_zpsqkjwridt.jpg) (http://s736.photobucket.com/user/major_major/media/D685E818-B320-4128-BE0B-FBEA0684EB3D_zpsqkjwridt.jpg.html)
The squiggly's with R are appropriate resistors, and that big thing was just my attempt at illustrating the latching switch and its posts lol. 

Now here's the addition of the kill key accent switch:
(http://i736.photobucket.com/albums/xx2/major_major/EC9F1D90-19AC-4F7F-9D2E-17CAEF341F08_zpsra111cju.jpg) (http://s736.photobucket.com/user/major_major/media/EC9F1D90-19AC-4F7F-9D2E-17CAEF341F08_zpsra111cju.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/A2C66BC7-1144-4943-AA16-81B445558EEB_zpsdp6vaysm.jpg) (http://s736.photobucket.com/user/major_major/media/A2C66BC7-1144-4943-AA16-81B445558EEB_zpsdp6vaysm.jpg.html)

Wiring design has officially been approved by the masters lol!  Special thanks to all of you, you know who you are, especially Kouri, for your knowledge and time :).  My understanding of these small electronics etc. would still be laughable if it wasn't for your coaching.  I was actually kind of proud of myself lol, I jotted this down, my best guess/ gut instinct about how to design the internals, and it was actually right!!  Another big help, aside from kouri's patience over the last few weeks as I did my homework and relentlessly shot him questions lol, were some books recommended by the one and only erv.  Forrest Mims III's "electronic formulas, symbols, and circuits", and also the Forret Mims circuit scrapbook-  SUPER helpful to anyone looking to get into working with and understanding small electronics.  So big thanks to erv as well! 

It's gonna be sweet- going to use a red illuminated latching AV mounted in pommel- switch light in parallel with main led in typical fashion, with an accent led wired direct/ always on and a recharge port cut into that circuit and wired in such a way that it won't be for recharging, but will instead act as a switch for the two accent led's.   I just realized it'd be cool to be able to shut the standby light off sometimes (like say during or right after charging, or like say your on way to a con, and you want to preserve as much power as you can till you arrive etc).  With the always on accent, as cool as it looks IMO, that's not possible- an inconvenient side effect.  But this 'switch' will give me best of both worlds- can have the accents shining away on my deactivated saber to really intensify / sell its look/ realism- but will be able to pop in a kill key and shut them off whenever.  Since the blue led in the bank will come on whenever there's a draw, and the accent led's constantly being fed, there would be 2 optional always on accents- one red one blue.   Recharge ports have three pins, a positive, a negative (irrelevant in this application), and a spring loaded pin that disconnects when the recharge plug/ kill key is inserted.  In a normal port, these work together to allow power to be channeled to battery without sending power to board/ rest of internals.  By simply wiring my positive lead to the positive pin, ignoring the negative pin and wiring my negative lead to the spring loaded pin, the kill key becomes that accent switch. 

Got a choke on the way that matches the sentinel style chokes, which I'll be using as a 2.5" extension at the pommel end, to give me plenty of clearance for the pommel mounted switch, and also my USB recharge port and kill key accent switch.  I'm excited about gaining those couple inches I've always wanted to feel down there... (LOL!!!) and also about how dramatically will change the look- will really exaggerate the segmented look of the sentinel- will be very exaggerated emitter/ body/ grip/ and pommel sections :).   

Keep you posted- MTFBWY.

Well lol... anyone else spot the GIGANTIC GLARINGLY OBVIOUS ERROR in my little makeshift diagram?  Hint: it's so obvious it's hard to spot... It's in the accent circuit.  For whatever reason, maybe because this is an unusual way to use the port, when I cooked it up originally I had the negative from the accent going to the positive post on the port (pin), which i wish I would have realized hours ago lol, before I checked and eventually redid everything a few times haha!  O well, live and learn.  It's funny how even staring at the wiring and following it I just looked right past that for so long. 

Turned out exactly like I was hoping though, so totally worth it :).  Now I'll scoop a knurled kill key, and a greebly I can place almost anywhere within reason becomes a functioning switch for the accents.  I'll have some pics of more progress up soon, but I better get to bed for the moment.  Here's just a super quick, down and dirty vid of how it turned out- I just grabbed that bit of wiring and strew it out on the table for the sake of showing... apologies for the poor quality, and the fact that I can barely speak lol, it was a long day, capped off with a hard fought but rewarding/ necessary battle.  I'll show more proper update soon- keep you posted, MTFBWY.

https://youtu.be/qFNi_TbSrB8

(Edit): o I forgot to mention a couple big things to put this all in perspective- it's a 5000mA bank, and the accents (switch etc.) are all parallel with main led- so all sharing the full voltage of the power source.  So if you think about those accents, 20mA, 20mA (switch led), and probably about 10mA for the blue one in the bank, it's not like you'd really have to sweat it that much :).  BUT, it's still cool to be able to kill them for sure.

Awesome job Rev, that's bada$$ keep up the good work, MTFBWY, point for you my friend

Thanks so much Joshie-Wahh!  Can't wait till your transistors come in-  excited to see your stunts transformation as well :), gonna be epic!  Point back at you.

Ok, here's a better look at it lol- again, sorry about the vid - I was so tired i could barely even think, let alone string a sentence together.

(http://i736.photobucket.com/albums/xx2/major_major/54D75616-E852-4256-A7E5-57939BC8ABE3_zps4dkc9zwq.jpg) (http://s736.photobucket.com/user/major_major/media/54D75616-E852-4256-A7E5-57939BC8ABE3_zps4dkc9zwq.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/CF0BC828-FE22-41B7-BC59-FCCC9428C52D_zpsgyjhptfu.jpg) (http://s736.photobucket.com/user/major_major/media/CF0BC828-FE22-41B7-BC59-FCCC9428C52D_zpsgyjhptfu.jpg.html)
Those other ends are where my switch and led come in.  Put quick connects on accent and port for convenience during installing/ testing etc., except at the USB because it's already pretty convenient popping in and out as is.  I don't have a 2.1mm knurled kill key yet so just using an empty/ unhooked charger plug for time being.  Keep you posted, MTFBWY :). 

Sorry for all these tiny updates lol, but I've got so much to do for this project, and with life being so good at keeping me swamped with all kinds of other crap to do all the time lol, I really need to take advantage of every little morcel of free time I get- so latley my progress seems to come in constant but small increments as I squeeze tiny bursts of work in on the day to day whenever possible :). 

As much as I liked the cover tech wheel placement and how it locked my hand in a good grip- now that I'm extending the pommel end of the hilt it's gonna have to move- won't look right floating oddly mid hilt, especially not when being worn.  So I'm taking advantage of the hole left behind and using black 8-32 set screws to lock the power bank in place.  The cover tech hole came to me with the blemish you see there, must have gotten nicked when they put it in, but I never cared before because was hidden under wheel.  Still doesn't really bother me much, as this thing's gonna collect an awful lot more of those in battle lol,  but I'm gonna touch up with blackener when I touch up the other little nicks (window/ box).  They'll all hide no prob :). 
(http://i736.photobucket.com/albums/xx2/major_major/4C55CBCB-4AD6-47E2-A191-21E6527F1794_zpszycaixmg.jpg) (http://s736.photobucket.com/user/major_major/media/4C55CBCB-4AD6-47E2-A191-21E6527F1794_zpszycaixmg.jpg.html)
That's grease on the threads if wondering, just looks funny with light shining on it.
(http://i736.photobucket.com/albums/xx2/major_major/13D83AA9-2D8B-4119-8C3E-554EBBF1FDB5_zpsucpnbuvg.jpg) (http://s736.photobucket.com/user/major_major/media/13D83AA9-2D8B-4119-8C3E-554EBBF1FDB5_zpsucpnbuvg.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/0B0167D1-63DF-47F2-A0CD-310F5E2E61A7_zpslf4us0j2.jpg) (http://s736.photobucket.com/user/major_major/media/0B0167D1-63DF-47F2-A0CD-310F5E2E61A7_zpslf4us0j2.jpg.html)
The two I tapped in- nice and clean.
(http://i736.photobucket.com/albums/xx2/major_major/6250CE65-9A8E-4649-ADD8-DBA0A0435A38_zpsicwdpz91.jpg) (http://s736.photobucket.com/user/major_major/media/6250CE65-9A8E-4649-ADD8-DBA0A0435A38_zpsicwdpz91.jpg.html)
The existing cover tech hole with blemish. 
This saber was a grab bag pull- so in a way I love that nick, since it's what brought this beauty home to me in the first place lol.  Be sad to see it go lol :). 

Decided against doing the chassis segments for the bank- mainly because not necessary.  Been testing, and this thing just will not budge.  I'm just gonna make some little plastic bushings to cover the exposed threads on the interior, a little extra short protection, will just be stubby little plastic tubes that fit around the threads.

   Looking down into this thing now, I'm feeling better about the install and the sheer amount of wiring that I'll have going in lol.  Because of how I'm wiring, and also where I'm putting everything all spread out, there's gonna be an AWFUL LOT of wire in here- and it'll be running back and forth, up and down the whole length of the saber and back every which way lol, so I'm glad that the bank's square shape inside the round hilt created these 4 channels which I can use to keep everything organized when it goes in.  It made these four nicely separated pathways, divided again by the set screws on three sides, and basically compartmentalized the main through-way for me :).  The inside of this bad boy, though cram packed lol, will be nice and clean! 

Keep you posted, MTFBWY.

Nice progress. I bet it's stuffed inside lol. Good tap job

Thanks Bulvoy :).  Yeah, it's gonna be INSANELY packed in there for a saber without sound, just because of the the extra loop for the switch accent light, the loop for the direct accent- made more cumbersome by the kill key, and also the wires for the actual recharge recharge port (micro USB) and the rigged up USB port itself.  The banks input is a micro USB (800mA at 5V), so I'm running one out to a female USB micro to female USB adapter I'll be rigging up as the port and mounting somewhere.  That way the charger's micro USB will just plug conveniently into a jack/ port on the outside of hilt same as normal ports.  All that in there (plus obviously the switch leads and main led leads) with the addition of quick connects on most of the components makes for one LOADED stunt lol. 

Keep you posted :).

It took 3 drill bits before the idea that these pieces were hardened/ tempered steel got through my thick skull lol.  Three pointed dremel grinding stones and one pointed burr later and I had my screw hole... But now I need to go grab more grinding stones and another burr before I can continue lol I'm out. 

I'm not using this screw, I just didn't have any 6-32 black set screws handy, but those will sit down flush/ invisible and preserve the right look.  Also I still need to grind/ clean up the one side and repaint the whole piece black- it took quite a beating in process lol.  One last thing, the wire's not actually running exactly like this, just popped it in quick to show.  Ok... That just about covers everything lol- basicaly there's still a long way to go here on this aspect:
(http://i736.photobucket.com/albums/xx2/major_major/EC45D935-1608-463B-B8E7-A960C95C5EE6_zpsillamqyh.jpg) (http://s736.photobucket.com/user/major_major/media/EC45D935-1608-463B-B8E7-A960C95C5EE6_zpsillamqyh.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/8DACDA52-3225-4D96-8E59-6D2F728AB294_zpsmeuqfsdp.jpg) (http://s736.photobucket.com/user/major_major/media/8DACDA52-3225-4D96-8E59-6D2F728AB294_zpsmeuqfsdp.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/E2453CC0-C4A3-454D-9791-69C2AA2018DD_zpsjbehkeho.jpg) (http://s736.photobucket.com/user/major_major/media/E2453CC0-C4A3-454D-9791-69C2AA2018DD_zpsjbehkeho.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/3D2AEA97-95D0-48BC-88BB-CC9426C46CD5_zps719oyead.jpg) (http://s736.photobucket.com/user/major_major/media/3D2AEA97-95D0-48BC-88BB-CC9426C46CD5_zps719oyead.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/1C9B4BAD-D2AF-45B5-B2CC-D0B970BC362D_zpsiavgowrx.jpg) (http://s736.photobucket.com/user/major_major/media/1C9B4BAD-D2AF-45B5-B2CC-D0B970BC362D_zpsiavgowrx.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/DC1EBCD0-22D6-4B11-9280-38E407409BE8_zpszpaxkhvv.jpg) (http://s736.photobucket.com/user/major_major/media/DC1EBCD0-22D6-4B11-9280-38E407409BE8_zpszpaxkhvv.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/FAE16D32-0001-48AB-8BBB-DB343A43803F_zpscna1cpfx.jpg) (http://s736.photobucket.com/user/major_major/media/FAE16D32-0001-48AB-8BBB-DB343A43803F_zpscna1cpfx.jpg.html)
Gonna pick up those set screws tomorrow morning probly on way home from work.  Will look WAY better with that in!  Keep you posted- MTFBWY :).

Revan, maybe I missed this.. Is your external wire going to have a functional aspect or is purely aesthetic?

That is nice looking. Just hope non of the inner wires never become exposed x.x

Hey Greg :).  The idea was mainly for looks- I've been studying a lot of ref pics of kylo's hilt for a build I'm doing ATM, and the influence krept in- also I'm going to have to do a lot of this stuff for that kylo build so this mod was a way of testing ideas before hand if you know what I meAn. 

At first I REALLY wanted to run one or two of the functioning leads there, but after a ton of testing I had to give that idea up.  If this saber was gonna be a display only, 'shelf queen', then I would have 100%.  But since it's my main dueler- it would have been too delicate/ liable to cause problems.  About the thickest wire I think anybody would ever use on a saber is 18AWG, that's really thick- the kind of heat you need to get that wire to take solder would almost certainly transfer up the wire and burn components if not using a soldering heat sink.  And if you tried to solder it to a board, you'd inadvertently bridge all the pads in the area just because the wire has such girth lol.  Most ppl stick with 26/28AWG, maybe 24 (what I used)- which is drastically thinner/ flimsier.  This thinner/ flimsy wire, even with a bunch of bracing on the outside of hilt and even with a bunch of extra slack sitting inside the hilt at exit/ entry points, would almost certainly get yanked all around too much.  Like even just from the squeezing of grip, over time it would start to stretch and pull and put stress on solder joints and connections to components.  And like even the 18guage, though arguably too cumbersome, bulky, and rigid to be practical for use inside a hilt, is still a tad too light for me to be comfortable with how it'd fair under that much stress. 

The wire I'm using is 10guage, I think, or 12- King Kong wire lol- acts more like speaker wire or craft/ fencing wire.  Once bent to shape, it'll want to hold that shape surprisingly stubbornly, even when subjected to pressure.  You pretty much have to take it between two hands or in pliers and intentionally bend it to get it to flex.  It's perfect for this application, since it will pretty much stay where I run it, with a little bracing.  It'll hold up- and since it's not functional, it's no biggie to just patch up as needed :). 

And thanks Zren :).  Exposed wire inside ANY hilt would be bad, since the hilt walls and most components are metal- but there's actually nothing in particular about this hilt that'd make it especially dangerous/ vulnerable that way.  Actually I've all but eleminated the risk by trimming back any threads flush with the inner walls so nothing sticks down into hilt at all except for the power bank set screws, which I have concealed inside plastic bushings so no exposed metal :). 

Picked up those set screws- IMO looks way better without that big ol' silver button head sitting on top :). 
(http://i736.photobucket.com/albums/xx2/major_major/640D5327-AFB4-4117-946B-F85D8A965062_zpsaczvaq0d.jpg) (http://s736.photobucket.com/user/major_major/media/640D5327-AFB4-4117-946B-F85D8A965062_zpsaczvaq0d.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/4AC83C7A-CE63-47DD-8614-6C79718E5C88_zpswa3chxiz.jpg) (http://s736.photobucket.com/user/major_major/media/4AC83C7A-CE63-47DD-8614-6C79718E5C88_zpswa3chxiz.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/BDEEB559-1976-42AB-97CC-0CB6EC3B8045_zpsjxcwnb6q.jpg) (http://s736.photobucket.com/user/major_major/media/BDEEB559-1976-42AB-97CC-0CB6EC3B8045_zpsjxcwnb6q.jpg.html)
Keep you posted, MTFBWY.

Looking great bud


Sent from my iPhone using Tapatalk

Its really coming along beautifully.Nice work!

Thanks guys!  Really appreciate :). 

I'm super excited/ anxious to get a start on the last major structural component of this mod: the USB recharge port- got a really cool idea for it I'm gonna try out.  I've had thoughts about doing something like this before to add a crystal chamber to a saber, but haven't had chance to try out yet- so this will be the perfect opportunity.  I think for a crystal chamber I'd have to go much more elaborate, but something rudimentary will suit the nature of this project best I think- and probly best to go as simple as possible on my first attempt at something like this, since going to be fairly tricky I think.  Don't want to ruin the surprise TOO much, so all I'll say is that I've got some brass narrow hinges ready to go, and my dremel finger is itch'n lol :). 

I've also got to mount the AV switch and kill key port still- not underestimating that task.  Normally I think this would be fairly easy, but I have a feeling that available space will make it a bit tricky on this one.  I'd like to put  the kill key down in, or at least near, the pommel too, but I'm not sure it'll fit.   We'll see.  got other 16mm switches here but I wanna wait till I'm holding the actual switch in hand before I make any holes.  Just like for the USB port- I'm dying to start cutting lol, but my better judgment tells me to wait till I've got all my parts sitting in front of me and ready to go so that I can be sure everything works out properly- last thing i want to do is get ahead of myself/ impatient and wreck stuff at this point.  Exact placement of some of these things isn't finalized for same reasons, until I can confirm everything's gonna fit properly.  But I do pretty much know how it's gonna go, so once I double check it should all come together pretty quickly. 

For now I'm just gonna finish the last three lines (well, first three lines really) of the sith code, and then go back over with the scribe to clean up etc.  That'll be time consuming, so it kinda works out perfectly- with any luck I'll have that wrapped up by the time the last few parts are here.  At the same time, my gears are pretty much whirling madly around the clock about the last few decisions to be finalized lol.  So good to have the time to let that digest at the back of my mind while I'm getting to some of the accumulating little unfinished aspects.  O, like the blackening to hide the scratches/ blemishes- almost forgot about that! 
Keep you posted- MTFBWY :).

That red wire tho!!


Sent from my iPhone using Tapatalk

hi everyone :)

well, again i have to say sorry for the quality of this vid- my phone died so had to take on old i pod with terrible camera that couldn't even get to focus lol.  was just running too short on time to do proper treatment, ill update the log proper soon.  but just to give you quick rundown anyway.  been playing around/ experimenting for some of the final little touches- at least what i can do until I've got everything handy.

https://youtu.be/DevAOsU9zpI

i couldn't live with that terrible camera lol, so heres a couple at least from my phone while was charging, so that at you can see a focused shot of the area:

(http://i736.photobucket.com/albums/xx2/major_major/IMG_1113_zpstgl0nofo.jpg) (http://s736.photobucket.com/user/major_major/media/IMG_1113_zpstgl0nofo.jpg.html)

(http://i736.photobucket.com/albums/xx2/major_major/IMG_1120_zpspsfgd4nu.jpg) (http://s736.photobucket.com/user/major_major/media/IMG_1120_zpspsfgd4nu.jpg.html)

(http://i736.photobucket.com/albums/xx2/major_major/IMG_1121_zpsvu47jrx1.jpg) (http://s736.photobucket.com/user/major_major/media/IMG_1121_zpsvu47jrx1.jpg.html)

will post up a clearer, more organized look at everything soon- MTFBWY :).

What comes next? Lol

Sorry, been swamped with work n arlo, and also trying to get the training back in gear- I run competitively and do extreme races etc. 



HAHAHAHA- is that a subtle way of saying move along we're all sick of seeing this part lol!?  ;).  That's fair lol :).  But I think you really do have to stop and dwell on these little things, mess with over and over until you get just right, along the way as the situation demands.  A wise smith once said,"If you rush it you wreck it"- totally true.  i really have to test this before i can finalize, because I need to know if there's room in my bank's output for all these accents, or if the over draw of current will trip the protection circuit.   It'd be a shame to spend a ton of time doing this whole feature up, and to do some undoable things to the hilt in process, and then find out the bank can't run it lol!  But I don't have an illuminated latching switch handy yet (on way) to hook it all up, plus I need to wait for extension for sake of strategically measuring wire etc anyway, so I'm gonna just use the current latching switch, but cut in an extra accent to pose as the new switch accent for the sake of testing, and then connect EVERYTHING all up and find out what she can take lol.  Then I'll have the go ahead to finalize this bit, which along with the engraving and odd jobs mentioned in vid, should take me to when the last parts arrive :).  Then hopefully I'll be doing the port!  Excited/ scared about that lol. 

Was talking to the pros and Kouri pointed out that the 3V from my tester packs wasn't quite enough to get the DynaOhm to give the full brightness on the accent-  pleased to see what a noticeable diff he was taking about: popped in higher voltage 14500's:
(http://i736.photobucket.com/albums/xx2/major_major/B4E54121-C613-40B1-BAEA-9E41C94C7D2D_zpstqhm6w3s.jpg) (http://s736.photobucket.com/user/major_major/media/B4E54121-C613-40B1-BAEA-9E41C94C7D2D_zpstqhm6w3s.jpg.html)
Even in bright overhead lighting it's quite a bit brighter.
(http://i736.photobucket.com/albums/xx2/major_major/1C69A9B1-E92B-4A40-92AE-D858CF998F20_zpsf2x8yyi0.jpg) (http://s736.photobucket.com/user/major_major/media/1C69A9B1-E92B-4A40-92AE-D858CF998F20_zpsf2x8yyi0.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/F969FEDB-9CCA-4C57-977C-ECCDEF7CB71D_zpsmw4aaxqz.jpg) (http://s736.photobucket.com/user/major_major/media/F969FEDB-9CCA-4C57-977C-ECCDEF7CB71D_zpsmw4aaxqz.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/57E725D4-B5EF-4FA2-9116-83524FE4AE22_zpsolwu6tei.jpg) (http://s736.photobucket.com/user/major_major/media/57E725D4-B5EF-4FA2-9116-83524FE4AE22_zpsolwu6tei.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/2AFD8731-72E4-43BC-BEFF-0E7F2A5EE2BC_zpsnnmfz9rr.jpg) (http://s736.photobucket.com/user/major_major/media/2AFD8731-72E4-43BC-BEFF-0E7F2A5EE2BC_zpsnnmfz9rr.jpg.html)
Be wrapped up today with obligatory stuff, but in evening gonna hook up that whole test- not looking forward to in way cause a ton of hooking stuff up that just gonna have to take right apart again after- but gotta confirm this idea will work 100%- anxious to know cause it's pretty wicked lol :).  Keep you posted.

Holy cow all those lights look awesome!

Haha! I didn't mean that offensively! Sorry if I offended you!

I was simply making a fun little poke at you because you've done so much to the saber that I was excitedly anticipating whatever comes next.

It really does look great though!

Dauntless!  How the heck are you lol?!  We've missed you around here- the place somehow just didn't seem quite as bubbly/ friendly without you :).  Thanks- yup, actually arlo's doing great.  I had him down at the dog park this afternoon and he was chasing and trying to hump all the other dogs for hours :).  I just let it go because I'm going to have to get him fixed for health reasons, a hormone thing, so I couldn't bring myself to stop him this time lol.  I think the other owners were getting annoyed! 

Thanks Hansrad and Greg!

O no Greg- not at all, no worries!!  I was honestly cacking up :).  I'm not easily offended anyway, not at all.  My friends and I are always joking around / ripping on eachother, etc.  Plus your post was'nt offensive at all lol, I was just laughing cause my first reading of it was like, man that's gotta be the most friendliest, subtle way of saying 'ok already, frick'n move it along!'  Lol.  Then I was like, man he's right lol!! All good buddy, was funny :).   Thanks again for the kind words.

After the dog park we swung by a pet store to use their bathing facilities, WAY easier,  and when we got back arlo passed right out lol.  I was a hot mess from the muddy dog park and from bathing him- it's like bathing a furry, unwilling person lol.  But I still needed to go do laundry because I had no clean clothes to change into after I showered-  I packed up all the laundry but then I was like- 'meh, I'm just gonna go set all the stuff up on the bench for when I get back lol... And next thing I knew I was just tearing down the wiring to redo, organized in a way that works for this idea.  I had to know if there was room in the output- because there's essentially gonna be three or four accents if you count the bank's blue/ red status indicator, and I realized it was gonna add up- plus I found out that the main led was actually running hotter than I first thought.  The time really got away from me lol.  Took me a while to realize what the smartest layout was for the wiring, so that everything would fit obviously, but also so that things could be removed/ installed without big ordeal, etc.  Was tricky getting all this in and getting right distances of wire for things to do what they needed to do without getting in the way... Hard to explain, but Because of the positions of some of the components relative to eachother, and because of how I chose to wire it, the wire really goes back and forth, back and forth in there a bunch, squeezing through an awful lot of stuff all relying on same tiny through ways lol.  And putting it in reminded me of doing a rubix cube, or a game of chess against the computer on expert- every move had to be perfect lol, every call about wether to go this way or that way around or over or under that connection or this one proved to be pain staking to say the least!  I actually had it about 80% in and realized a couple splices should be moved so had to take it all out again (which takes longer than putting in, it turns out lol) and redo.  But I got it :) !! I've got everything hooked up, and it's all set so that when the AV and extensions arrive I can solder in with much less fuss. And even better news, is everything can run off the bank's output and then some. I had the two red accents, and obviously the bank's led, plus another salvaged accent (in case I want to put one in the port hatch when I get there, I need to know it's doable now), plus the main led, plus I wired in an illuminated momentary I had here but just the accent posts to stand in for the latching one that's on the way- all running no problem. 

Thrilled!!! If someone would have been watching it would have looked like I spent hours redoing the same stuff into diff versions of the same thing, and not having much to show from it- but for me, this was the most singular 'victory' type moment of the whole project, because once I figured out that it could in fact JUST be made to fit, and when I saw those lights all come on and stay on, that was the exact moment that I knew this whole project was actually going to work lol!! Up until now it's just been a wing and a prayer kind of thing, flying by the seat of my pants and being pretty sure it'd work- but the more elaborate my ideas became the less I could really say for sure one way or other.  This was where i officially knew I could pull off.  Was a battle but totally worth it... Even though now that I'm finished its 2am here, laundry mat's in my small town all closed, so I'm stuck in a ripped up pair of old drawers I thought I already threw out and a dirty t shirt till morning lol.  But I'd do it again :). 

It looks great, Rev! Seeing it all lit up is definitely a treat  :D

Thanks Sedsti!

Testing some of the quirks of the bank in this set up-  scared me last night at one point- when the bank got low it's blue status indicator died, which would have been totally normal IF the thing cut itself off the way it's supposed to when pooched lol.  Everything just kept on running, albeit dimmed and dying, except the indicator shut off.  The bank itself is actually supposed to cut off, not just the light- but so long as I always notice the light die and stop to charge at that point it's all good. 

I think by the time I get this thing done I'll officially be able to call myself a cram-foo master lol!  Wanted to give you a sense of what I'm up against-  I've got the bulk of the wiring in place and all good to go.  The main led, switch, and port are all ran through where they need to be, just sitting out waiting for the extension and pommel to be completed and then they can be stuffed in right from where they sit now.  The grey micro USB will be Frankensteined into port, and then I've gotta get that back thru somehow lol.  But when you look at those pics, notice all the stuff hanging out, and realize that the inside of that hilt is ALREADY stuffed solid with wiring lol!!! I'll have JUST enough room to coil up everything sticking out pommel and house in extension- the main led will go in last- the cork to the bottle of champagne that is the wire in that upper body section lol.
(http://i736.photobucket.com/albums/xx2/major_major/868CD87E-5117-42C3-8247-CC2509703A26_zpswh3shcpj.jpg) (http://s736.photobucket.com/user/major_major/media/868CD87E-5117-42C3-8247-CC2509703A26_zpswh3shcpj.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/519122D6-4DB7-4388-BA64-06EC4B60BE0F_zpswq7kmuur.jpg) (http://s736.photobucket.com/user/major_major/media/519122D6-4DB7-4388-BA64-06EC4B60BE0F_zpswq7kmuur.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/5BCFF202-2144-4B55-AE5F-C78AEAB284F3_zpsd8qqxmqy.jpg) (http://s736.photobucket.com/user/major_major/media/5BCFF202-2144-4B55-AE5F-C78AEAB284F3_zpsd8qqxmqy.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/59DA1BFE-17B9-47F8-A303-D6A9F1116D06_zpsv6fectqt.jpg) (http://s736.photobucket.com/user/major_major/media/59DA1BFE-17B9-47F8-A303-D6A9F1116D06_zpsv6fectqt.jpg.html)
Here's what it looked like charging:
(http://i736.photobucket.com/albums/xx2/major_major/3A0250D1-B2B6-41E1-8314-8EADF5BF43ED_zpsq4p5llkm.jpg) (http://s736.photobucket.com/user/major_major/media/3A0250D1-B2B6-41E1-8314-8EADF5BF43ED_zpsq4p5llkm.jpg.html)
Keep you posted- MTFBWY :).

Nearing completetion. Looks sweet.  Is there enough room inside for any air? Lol

Wow Rev! A lot of work since the last time I saw this post. Pretty much a week after I got my first saber. Is that too much wire or does that hilt allow for that? How long is the grip section also, 1.24"wide? I have an idea for a build but its for a Bellicose. I need like 7" for the 2x18650 battery pack chassis alone!

Great mod and looking forward to more updates. +1

Looks awesome bro! Lots of inspiration!


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Looks awesome bro! Lots of inspiration!


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Thanks guys, really appreciate the encouragement!! 

Yeah, my internals must be feeling mighty claustrophobic right about now lol- the hilt is pretty much an anaerobic environment at this point- just a solid tube of wire lol :). 

Hey Calculon, I'm pretty sure you're right about the 1.24" ID- and I'm not exactly sure about the length of grip section (guessing about 6") off the top of my head- I'm at work ATM- but I get done in about 6 or 7 hours, and I'll def grab a tape and a micrometer and take some precise measurements for you quick when I get home in morning :).  I'll send u a pm with that in morning for sure.

As it sits right now there's not quite enough room in the pommel end for the amount of wire that's there- but the extra 2.5" I gain from extension will give me the little extra I need to keep some extra/ play in wires so everything can be slid out the ends for undoing the jst's and removing the wiring if ever need to.  At the emitter end I'll def be ditching a good portion of the micro USB wire and the extra wire attached to main led before installing for good- it can be crammed in as it is now (barely lol!) but gonna make life easier for myself and cut some down when I get/ hook up the latching AV etc. 

Keep you posted- MTFBWY- and really looking forward to seeing your guys latest work too :). 

Actually celebrating right now.

Just rewired a new LED into the kids saber. She got tired of the GB and wanted a SRD so wired up one of those after completely putting her hilt together.

Then, I had to remove the wire harness on her NB3 because a pin failed and broke up in the harness (that was weird).

Soldered everything in... backwards... (seeing your green die lit up like a accent light is a good sign you need to stop!)

Did some crappy solder job to test everything for a 4th time and (lightsaber sound), back in business.

Gotta clean up some joints but it is so much better having gotten rid of a useless JST and about 3 in. off every wire... almost every wire.

So much trouble but well worth as I'm sure you know. I think a level up is coming soon.

Just heard back from US about drilling an extra switch hole for a aux button and thats a no go.  Hope the Bellicose hase 8" before the switch... or that theyll atleast accomodate my request to place the switch at a certain spot.

As far as progress updates go there's not a ton to show here- BUT I thought one thing in particular was worth sharing because I think it's a cool idea a lot of people could use in their modding.

Remember that pic way back of the burnt florescent tube I took the pins out of?  If you look there you can see this plastic tubing that's designed to encase the bulb and contain glass if breaks... Turns out they fit perfectly inside the typical ID of mhs hilts.  Now i'd hesitate to call this a chassis material, though I'm sure could be worked into one, but more like a non conductive shielding for internals.  Basically you can swap the metal (short potential) inner walls of your hilt for some nice safe plastic :). Plus it'll kind of contain the wiring.  This type thing would be especially handy if you were installing your own clash sensors etc- they sit suspended in your wiring and swing around in the inside of your saber by necessity, personally i'd feel a lot better about them banging into this plastic than into the aluminum.  And if your doing any kind of window- like for a crystal chamber, or pli, or something like what I'm doing here- really puts a nice finishing touch on it:
(http://i736.photobucket.com/albums/xx2/major_major/7A5B5D22-0226-449E-9DB7-1D867D039EE2_zpsrjv0knvm.jpg) (http://s736.photobucket.com/user/major_major/media/7A5B5D22-0226-449E-9DB7-1D867D039EE2_zpsrjv0knvm.jpg.html)
Side note- of the projects I have going ATM, this one's closest to completion... Closest is a relative measure lol, there still a ton left on this thing, as evidenced by the depressing lack of check marks on that list if you can make it out lol!
(http://i736.photobucket.com/albums/xx2/major_major/399913AC-5506-4581-9376-63C925D1B4C1_zpsv0elhgym.jpg) (http://s736.photobucket.com/user/major_major/media/399913AC-5506-4581-9376-63C925D1B4C1_zpsv0elhgym.jpg.html)
I actually had to cut the insert up to lodge strategically into the top face of the bank because of the shape of the bank and how tightly I fit it.  But gonna work great :).  I just stuffed it in for these pics, it actually has a nice perfect/ gapless fit when you take the time to fuss with it.
(http://i736.photobucket.com/albums/xx2/major_major/F9E547A4-41EE-475B-80D3-01E9B38929F8_zpsnta9apfz.jpg) (http://s736.photobucket.com/user/major_major/media/F9E547A4-41EE-475B-80D3-01E9B38929F8_zpsnta9apfz.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/F789F076-4B1E-4A93-A7E0-7522B99734FF_zpsorwspv3x.jpg) (http://s736.photobucket.com/user/major_major/media/F789F076-4B1E-4A93-A7E0-7522B99734FF_zpsorwspv3x.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/772ABA51-73A5-4A3C-8B0A-904E01CB6301_zpsuzbrukef.jpg) (http://s736.photobucket.com/user/major_major/media/772ABA51-73A5-4A3C-8B0A-904E01CB6301_zpsuzbrukef.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/4C9E327B-09CD-4CB3-8739-3A552AA804D5_zpsk8bkjxiw.jpg) (http://s736.photobucket.com/user/major_major/media/4C9E327B-09CD-4CB3-8739-3A552AA804D5_zpsk8bkjxiw.jpg.html)
I didn't get pics of it, but the window actually really helps reflect the illumination from the hidden accent that washes over the bank, and it looks a whole lot more saturated with it in place :). 
(http://i736.photobucket.com/albums/xx2/major_major/BDBD7C1A-4FC6-4970-8B41-6AF23381B45A_zpso6jwb2xi.jpg) (http://s736.photobucket.com/user/major_major/media/BDBD7C1A-4FC6-4970-8B41-6AF23381B45A_zpso6jwb2xi.jpg.html)
Good thing I'm tantalizingly close to being done with roughing in the aurebesh with the electric engraver lol, doesn't look like my reference tape's gonna make it much longer lol.  I decided I might as well tap a set screw to hold the led module securely in place.  Man, is it just me or did this mod end up requiring an awful lot of little holes?!
(http://i736.photobucket.com/albums/xx2/major_major/6478CFB8-CDA3-4CAE-B9E8-027E729DBC41_zpsv5iedoum.jpg) (http://s736.photobucket.com/user/major_major/media/6478CFB8-CDA3-4CAE-B9E8-027E729DBC41_zpsv5iedoum.jpg.html)

Keep you posted- MTFBWY :).

Have you thought about replacing all those retention screws with knurled screws in order to give it a more aesthetically pleasing look?

Keeping up with your progress Rev . . . . and I bet the window does look awesome illuminated through the clear tubing, that is a great idea . . . . +1  :)

What was that clear tubing for?(saw you mention light bulb but could find pic) I found something similar but it way thicker than that stuff, using it for double crystal chambers on saberpike, but that tubing is a great idea to cushion impact as well as aesthetic reasons.

Thanks guys :).  Greatly appreciated!

  You know, I did actually think about that Greg- and I might still opt for a knurled thumb screw on one or two strategically placed spots- like say for the led module screw or wherever happens to look right.  But there's just so many, and they all kinda had to go where they sit now- like I was limited in where I could locate them since was all about function, like securing various things- and I think it'd be too busy if I put too many knurled screws in.  But I'm not too worried- for one thing I used black set screws, and also they'll be sitting flush to the surface of a black hilt so they'll blend in really well.   I just had them all sticking out in those pics, but won't look like that when everything installed :).   I mean you'll def see them, but they won't stand out.  And like the one in the choke for instance gets pretty much completely hidden by the little wire strap/ wire holder feature I rigged up there.  Call me crazy, but I think all the little flush black set screws will give it kind of a Frankenstein vibe, especially when combined with the exposed wire, cut away detail, etc- which is perfect for this project :). 

But, I def will be considering a knurled for one or two- good thinking Greg- thanks for the input :). 

The clear insert is a nice addition and should help protect those fancy internals you installed  ;)

With every step this saber gets that much better! You're doing great stuff, keep it up!

Hey Gilgamesh :). Sorry I missed your post there at first!  Yeah it's hard to spot anyway in the pic, and to be honest prob not worth digging that far back lol- it's just from a florescent light- I scooped a bunch of burned out/ dead tubes from work- salvaged the brass electrical pins out of them (ones in act box), which was my main goal- but when was tossing out the remains something just told me to keep a few lengths of that shielding... Must have been the force lol ;).  That's what sits around the lights, you'd prob never notice it in most cases, to contain any glass if a tube were to break- they're pressurized, so if one were to get hit with something (or when you break them to remove pins lol) they pretty much explode lol.  In a public place or somewhere with high ceilings, or anywhere particularly sensitive to contamination/ debris, they'll prob have these shields in place. 

If you meant , what am I using it for- ya just for finishing touch on the window to power bank, to give it a true window.  I figure if a real saber were to have a feature like this, it'd likely have to be protected/ sealed with transparisteel (spelling?) or something like that from SW universe.  This stuff is super thin, so it gives the look of an actual window, like very clear, in person depending how light hits sometims u can't even see it.   And added bonus of acting like bit o cushion and short protection :). 

Thanks Sedsti :), appreciate the encouragement/ motivation! 

Getting as much done as I can on this until I've got the last of parts (hopefully soon).  Decided on one of the three latest plugs from Sedsti I recently grabbed.  Not gonna go too crazy showing because I'm gonna put up a post in Sedsti's thread soon as sort of a mini demo of them.
(http://i736.photobucket.com/albums/xx2/major_major/EF119AAD-FA99-431E-BA7C-A3FDC1EB2663_zpsdkxrtqix.jpg) (http://s736.photobucket.com/user/major_major/media/EF119AAD-FA99-431E-BA7C-A3FDC1EB2663_zpsdkxrtqix.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/660C9B7B-1E16-4E8D-A9A9-035645F5F5FA_zps6lpuzaw3.jpg) (http://s736.photobucket.com/user/major_major/media/660C9B7B-1E16-4E8D-A9A9-035645F5F5FA_zps6lpuzaw3.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/80DF4ACE-03C6-43A1-8313-DC27ED41E178_zpsgxfegkax.jpg) (http://s736.photobucket.com/user/major_major/media/80DF4ACE-03C6-43A1-8313-DC27ED41E178_zpsgxfegkax.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/719A66D0-BE9A-4C4C-98E1-2DE4E5F6D270_zpssvzy9oz3.jpg) (http://s736.photobucket.com/user/major_major/media/719A66D0-BE9A-4C4C-98E1-2DE4E5F6D270_zpssvzy9oz3.jpg.html)

So here's the basic idea behind all these crazy accents and features, kill key, etc.  Here it is off- no drain at all with kill key in. 
(http://i736.photobucket.com/albums/xx2/major_major/EECDD5A1-1480-4C1F-9216-454189C95DAF_zpsq9lye034.jpg) (http://s736.photobucket.com/user/major_major/media/EECDD5A1-1480-4C1F-9216-454189C95DAF_zpsq9lye034.jpg.html)
You can see I finished roughing in the aurebesh, but nowhere near done with it- actually you can really see where I've started to go back over with scribe (only just started) and what a diff that makes.  That chopstick in top right of pic has proven to be the handiest tool in weeks lol- you know how Jedi use the force to align the inner workings of their sabers with molecular precision?  I pretty much had to do the same thing to get all this stuff in or out lol.  Only I haven't quite got the knack of levitating everything in a cloud of parts and converging it all gracefully into proper places... so the chopstick really helps lol. 
that guarded latching and all that wire on right side up there will pretty much be eliminated when the proper switch goes in.  Was having trouble getting the bulky micro USB in, but found this ribbon type/ flat cable at the corner convenience store and was exactly what the doctor ordered. 

So for dueling purposes, you just leave the kill key in and fire her up:
(http://i736.photobucket.com/albums/xx2/major_major/A277BF11-5B39-43F2-AD4C-9DDECBE3BD0B_zpsrhmi9hr6.jpg) (http://s736.photobucket.com/user/major_major/media/A277BF11-5B39-43F2-AD4C-9DDECBE3BD0B_zpsrhmi9hr6.jpg.html)
In this dueling mode, as I like to think of it, only the bank's status indicator and the illuminated switch down in the pommel come on, a nice compromise of craziness/ accents spread out across hilt, leaning towards saving most of the juice for the blade. 

When your done slaying foes, just pop the key out and throw on the stand, in display/ shelf queen mode:
(http://i736.photobucket.com/albums/xx2/major_major/928FCE4F-D4B0-435A-8DE7-3C8C1D5B816A_zpsglcyavfz.jpg) (http://s736.photobucket.com/user/major_major/media/928FCE4F-D4B0-435A-8DE7-3C8C1D5B816A_zpsglcyavfz.jpg.html)
As well as what you see here, there's also a little 3mm led going in a hole in the hilt on the opposite (act box) side, and another of those red illuminating accents that I used in the cutout for bank, going in the recharge port access.  So if I can pull off the access hatch, I'll be able to leave it open when on display, looking all red'ish and lit up lol.  Tested and you can leave it lit up with all these accents for days.
With the window in there's a much more dramatic colour mixing that happens from the red and blue accents- liking that- the window's here to stay :).  Plus will keep stuff out.
(http://i736.photobucket.com/albums/xx2/major_major/0BB0B583-3739-4F8E-B5FE-C4483F7A0D6B_zpsxcwnyci4.jpg) (http://s736.photobucket.com/user/major_major/media/0BB0B583-3739-4F8E-B5FE-C4483F7A0D6B_zpsxcwnyci4.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/68E16BD9-2C6F-4F7F-B8AD-69C56E08DBC1_zpsdmacotgs.jpg) (http://s736.photobucket.com/user/major_major/media/68E16BD9-2C6F-4F7F-B8AD-69C56E08DBC1_zpsdmacotgs.jpg.html)

And of course, you can always pull the key and fire her up, with this plus the 3mm, switch, and port accents- and the thing will light up like an Xmas tree... a sithmass tree lol, in all guns blazing mode.
(http://i736.photobucket.com/albums/xx2/major_major/54270F05-74CD-4666-84D4-42FFBE0A955D_zpsrrojbzbf.jpg) (http://s736.photobucket.com/user/major_major/media/54270F05-74CD-4666-84D4-42FFBE0A955D_zpsrrojbzbf.jpg.html)
I've tested and the bank will run all this... But I just don't feel really comfortable running it like that very much/ for any length of time.  Like I'd feel fine just for snapping some pics with friends at a con or something, but don't wanna push my luck dueling like this.  It's wierd, Ive quadruple checked this- most of these banks have a 1/ 1.5 A, 5V output.  This one, according to the info from the manufacturer, has an 800mA (0.8A), 5V output... Quadruple checked lol.  I'd be well within the limit of a 1.5A output bank's protection circuit- but 800mA? Lol something doesn't quite add up there lol.  I mean there's 6 20mA accents and a main led running at what 1000mA'ish, roughly- so ballpark 1.1/ 1.2A running on a 0.8A output?  I dunno I find it hard to believe that that's actually what it is- either way, it was like 3$ shipped lol, so I ordered 3 more as backups.  I've had these type batteries (NOT 18650!!!) explode on me before, literally, right on me and in my pocket, and I'm not worried about it.  Especially from where it's sitting inside the casing of the bank and inside the hilt- it'd just wreck the bank itself, not as dramatically as you would think, and that'd be relatively easy to swap out.  PLUS I seriously doubt that will ever happen- if anything I'd just kill it.  It's held up in testing, but I just plan on pretty much operating the saber in either mode or the other, either main blade OR all the accents for display, so it'll be fine :). 

Superb !  All wrapped up nicely. Sedsti's plug looms lime it was made for this one. +1

PARTS! sigh... Im with you man!

Its looking great! Again, great job with the window. Getting a nice crystal chamber vibe from it! If this guy fails me with what he's attempting to do to my grab bag; I'm gonna have to try something similar.

Wow wicked my friend. Taken me an hr to go through your log on this. Pretty amazing stuff. Tons going on  the display/queen refference  made me chuckle. I think a few of you custom kings should get together and do an ultimate combined project. I think my favorite part if I choose one is the window with the power light very creative. Have a point

DAT chop stick!

I can't thank everyone enough, truly appreciate!!  It always amazes me how supportive this community is, you guys always keep me SO motivated :).  Truly honoured by the kind words/ compliments!  Can count me in on the collaboration 100% krell- way in lol, so far in it hurts (...must...resist...pervy...jokes...ugh) lol. 

INCREDIBLE! Especially for dueling! Geez. Love the added lights, creates more depth. Well done!


Sent from my iPhone using Tapatalk

Thanks GQTatooed :)

Really appreciate!  Gonna put in some serious work to tomorrow so should have some more progress really soon.  Keep you posted, MTFBWY.

Looking forward to it.
And with you

Drawing nearer to permanently mounting a lot of this stuff, so time to decide on random things- like how exactly to fasten the red accent illuminating the bank cut out.  Originally I thought maybe just hot glue it in place on bank, but because of where/ how it sits I just wasn't comfortable with that.  Too much of a potential for it to settle into slightly diff position, and the alignment of that lens, how it aims the light in that window, is critical to how well the circuit card gets lit up.  So I was sitting there staring at the bank trying to think of ways to attach the accent really precisely and tightly/ secure, and I thought 'too bad this thing just didn't have a couple pads to solder the accent posts right onto it the way some circuit boards do'... Hmmmm, Rev, you accidental genius you!  So I reached over and grabbed a bag of random electronic guts:

(http://i736.photobucket.com/albums/xx2/major_major/748711C3-89CB-40D6-88C2-DC59321030C4_zps8srnzb4x.jpg) (http://s736.photobucket.com/user/major_major/media/748711C3-89CB-40D6-88C2-DC59321030C4_zps8srnzb4x.jpg.html)
Was originally going to a grab a piece from this- prob hard to see unless you can zoom in at all, but if you look down at very bottom of board, pretty much in middle you can see a black piece of a harness or something that's got brass pins sticking out and 1124 stamped on it- immediately to the right of that is where I was gonna cut a little piece out- two beautiful solder pads perfectly spaced out for the legs of an accent, with nothing else around for days and already isolated nice and everything (Looks like it was for attaching the legs of a resistor).  Just a side note- totally worth it to grab old junk, look how much useful stuff you can find- just in this board there's s bunch of female USB ports, a 2.1mm power jack down at bottom, some gold capped wires and the little plugs they snap into, etc. 

But two seconds later I found another one that I thought things would sit in better places with, so kinda eyeballed it:
(http://i736.photobucket.com/albums/xx2/major_major/0E7833C2-EBED-478E-94A2-CD5D47E67E5F_zpsmbp3oyin.jpg) (http://s736.photobucket.com/user/major_major/media/0E7833C2-EBED-478E-94A2-CD5D47E67E5F_zpsmbp3oyin.jpg.html)
Figured out where to cut.  I had to make sure I isolated the area I was going to turn into pads, or else I'd be running power to random unseen pathways in this circuit, which could easily make contact with things and cause shorts- so took couple mins to really carefully/ closely look at where everything went- you have to thuroughly cut through the surface of the pcb, NOT just scrape/ scratch it like you see here by the tip of scribe.  That was just to illustrate:
(http://i736.photobucket.com/albums/xx2/major_major/12146226-4019-44B9-AB22-49E0C101E554_zpsjqlkgvc9.jpg) (http://s736.photobucket.com/user/major_major/media/12146226-4019-44B9-AB22-49E0C101E554_zpsjqlkgvc9.jpg.html)
That's more like it- you can really feel when you're through the metal skin of printing on the pcb, and can clearly see if you look really close.  So then just bridged those pins/ pads into one pad for the accent connections each, and ran to those.  Just need to get some clear shrink and will be all good :).
(http://i736.photobucket.com/albums/xx2/major_major/E5C66E53-3864-4238-BBBE-49E0C400EDC8_zpsfcluqe3e.jpg) (http://s736.photobucket.com/user/major_major/media/E5C66E53-3864-4238-BBBE-49E0C400EDC8_zpsfcluqe3e.jpg.html)
Not like this area will be seen, really just a means of mounting accent, so guess doesn't have to be clear shrink, but I just like the way circuits look lol :).
(http://i736.photobucket.com/albums/xx2/major_major/F4FA041C-5310-45F4-B8FE-D3182E627758_zps3ffe1shi.jpg) (http://s736.photobucket.com/user/major_major/media/F4FA041C-5310-45F4-B8FE-D3182E627758_zps3ffe1shi.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/75328783-C07F-432D-BF59-0DBDCF0F108C_zpsj4vmck6a.jpg) (http://s736.photobucket.com/user/major_major/media/75328783-C07F-432D-BF59-0DBDCF0F108C_zpsj4vmck6a.jpg.html)
Kind of ugly joint but I didn't want to use real solder cause it's crappy outside and didn't want to open windows lol.  There'll be absolutely no pulling on these wires because of where they're located but gonna dab them both in place lower on board with hot glue into some divots I notched in the card for them to be extra safe, they'll be completely locked in this way.

With the accent properly mounted flush on the bank all precise and locked in place, it lights up like a BEAST lol!
(http://i736.photobucket.com/albums/xx2/major_major/3216D2B0-36EE-4E65-9B4E-6A49F5AEB3F6_zpst7ygol5k.jpg) (http://s736.photobucket.com/user/major_major/media/3216D2B0-36EE-4E65-9B4E-6A49F5AEB3F6_zpst7ygol5k.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/8D748B0D-EF35-4F09-AB89-EE6EF2B94F3E_zpsqhou8zfq.jpg) (http://s736.photobucket.com/user/major_major/media/8D748B0D-EF35-4F09-AB89-EE6EF2B94F3E_zpsqhou8zfq.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/2E3C61BC-CBE6-4FE2-92CF-A9291F8EA426_zps4sdtgfqe.jpg) (http://s736.photobucket.com/user/major_major/media/2E3C61BC-CBE6-4FE2-92CF-A9291F8EA426_zps4sdtgfqe.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/EC2CF80A-D3B1-46D1-AD5B-3D39579B8370_zpspubthxdc.jpg) (http://s736.photobucket.com/user/major_major/media/EC2CF80A-D3B1-46D1-AD5B-3D39579B8370_zpspubthxdc.jpg.html)
In brighter lighting I've noticed it tends to look more orange, but still looks cool.
Wax off...
(http://i736.photobucket.com/albums/xx2/major_major/6CA803A1-7403-49E9-92B7-8539B3713D62_zpsusu5jzhq.jpg) (http://s736.photobucket.com/user/major_major/media/6CA803A1-7403-49E9-92B7-8539B3713D62_zpsusu5jzhq.jpg.html)
Wax on...
(http://i736.photobucket.com/albums/xx2/major_major/E7E2D66D-B26C-4809-8DA9-BBDA790F9F75_zpsdpanjgkj.jpg) (http://s736.photobucket.com/user/major_major/media/E7E2D66D-B26C-4809-8DA9-BBDA790F9F75_zpsdpanjgkj.jpg.html)
Keep you posted- MTFBWY :).

Dauntless i'm with you on this.
Revan i find myself going over this  and start thinking what the ....... am I looking at? Doesn't matter I may not follow that well but I know I Love it.

Stellar looking, I really like how much of a reddish hue you managed to get shined through. probably a good idea going with hot glue in that area +1

As always just amazing!

Thanks so much everyone!  Very grateful for the support and encouragement :).  

I totally hear you Daunltesss and Shield Maiden lol!  I always took art and extra English lit classes, French, and that type thing- languages.  I sold my vehicle a while ago cause I live right up town and just barely used anymore, but used to drive me crazy that all I could ever handle was oil changes and changing tires etc.- simple stuff- meanwhile all my friends who took shop and auto etc. can all change their brakes and all kinds of stuff I'm clueless about.  

You know it's funny, it totally looks all crazy cause the ideas just kinda arose naturally/ on the fly, like I just let the back of my mind go nuts and start shooting out ideas from who knows where lol, and since using unconventional components in unconventional ways... But it's actually all quite simple/ run of the mill stuff in essence (albeit gone about in very unusual ways lol) :).  

That was kind of the whole idea behind this project though- basically just wanted to go off the deep end and see how far I could push/ how creative I could get with adding accent features and flourishes to a hilt- wanted this one to look like sort of a hodge podge of all kinds of mad science, alchemy, and like 'after market' upgrades so to speak- like I picture the wielder of this saber as a sith just absolutely obsessed/ to the point of insanity, just bent on relentlessly upgrading his weapon with power ups and hacks.  Like some kind of sith slicer/ hacker type, or like a weapons specialist, increasingly, narrowly fixated on the weapon in this spiral of madness fuelled by the dark side.

MTFBWY :)

dude love that weathered look...how'd you do that???

Thanks Mongo :)


Which- the ribboned fade pattern on the sentinel (sanded) or on the saber down in my sig (chemical treatments)?

While I'm waiting for the parts to ship, decided to start tinkering/ experimenting for the recharge port hatch.  It's not that anything involved on the port is all that difficult/ complicated in itself- but just made so by the insanely small area it'll have to go in- a choke, so basically the same 1" diameter as blade holder.
(http://i736.photobucket.com/albums/xx2/major_major/183D5409-2BCA-4965-A483-476FB549AC25_zps1n8mvsrm.jpg) (http://s736.photobucket.com/user/major_major/media/183D5409-2BCA-4965-A483-476FB549AC25_zps1n8mvsrm.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/8BE71C9E-F7D4-461C-A2A7-817A3A972718_zpsqn0fvxsn.jpg) (http://s736.photobucket.com/user/major_major/media/8BE71C9E-F7D4-461C-A2A7-817A3A972718_zpsqn0fvxsn.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/EFD73EFC-90FE-4C41-9672-F8871280FEB7_zpslrf1me4f.jpg) (http://s736.photobucket.com/user/major_major/media/EFD73EFC-90FE-4C41-9672-F8871280FEB7_zpslrf1me4f.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/0B7B06A3-CD50-40B8-9A0A-95BBEEDB91D5_zpss31xcfe7.jpg) (http://s736.photobucket.com/user/major_major/media/0B7B06A3-CD50-40B8-9A0A-95BBEEDB91D5_zpss31xcfe7.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/DFE9982E-A9BD-438F-93D7-1AA022D07B25_zpsgbkbad1w.jpg) (http://s736.photobucket.com/user/major_major/media/DFE9982E-A9BD-438F-93D7-1AA022D07B25_zpsgbkbad1w.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/6C3C3262-811A-4671-81F3-D673BF828B0F_zpscywbmttc.jpg) (http://s736.photobucket.com/user/major_major/media/6C3C3262-811A-4671-81F3-D673BF828B0F_zpscywbmttc.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/8E4FE5C1-A679-4C40-9915-62430D1EDF5D_zpssybfkche.jpg) (http://s736.photobucket.com/user/major_major/media/8E4FE5C1-A679-4C40-9915-62430D1EDF5D_zpssybfkche.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/45FE5C3C-96A9-4F08-84E1-E85000FFFE3C_zpskbtfdmv6.jpg) (http://s736.photobucket.com/user/major_major/media/45FE5C3C-96A9-4F08-84E1-E85000FFFE3C_zpskbtfdmv6.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/54038E9B-9472-48B5-9B2E-2C6464A6D260_zpscrtfzaen.jpg) (http://s736.photobucket.com/user/major_major/media/54038E9B-9472-48B5-9B2E-2C6464A6D260_zpscrtfzaen.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/54BDC731-D818-42FB-A401-F28EA9EEC7F5_zps9wzikloy.jpg) (http://s736.photobucket.com/user/major_major/media/54BDC731-D818-42FB-A401-F28EA9EEC7F5_zps9wzikloy.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/F4B3CAB9-5E41-4266-B49C-CFF6061A069B_zpsqi9ynic6.jpg) (http://s736.photobucket.com/user/major_major/media/F4B3CAB9-5E41-4266-B49C-CFF6061A069B_zpsqi9ynic6.jpg.html)
Awful long way to go here- basically just making this up/ designing/ test fitting as i go- then once I've got something done I like, I'll disassemble, dress it all up and finalize, but even this I suspect will need to wait till extension in hand.  But I can at least build all the components now and then just size the whole thing after.  keep you posted, MTFBWY :)

You seating that over your window or going custom pommel?

Was thinking telescoping reveal at the lowest choke, just above pommel :).  Got an mhs choke coming in to use as extension at bottom/ before pommel.  The switch and kill key would detach and slide back with the pommel and bottom half of the choke.  The top half of this piece will mount just at the end of power bank, almost at where the threads of the body and top (male) half of choke will be, and then extend down through the choke to insert into this one which will allow for the telescoping.  These ones here are 7/32 brass tubes, the top will be 3/16 with 6/32 threaded rod running through it for support (fills tubes nicely).  The top rods slide into the tubes of this one.  Haven't actually made the base that will be screwed through to mount top of any of that yet- ran outta time lol.  Still have to design this piece etc too.  This will be where Dressed up USB port will sit :).  Keep you posted.

I see it! Dude you're gonna have fun with a crystal chamber.

Thanks Calculon :).

Yeah, I'm totally having a blast with this thing already lol!  Gonna be challenge for sure, cause first time doing anything like this, and tight area, but totally fun/ exciting. 

Man Rev, you blow me away every time you update this project!

I seen this coming  ;D. Always fun watching this unfold nice , nice..

Thanks guys!  SLOWLY starting to be able to see where I'm going with this- the base will get a coat of metallic gold, and with all the brass, there's a really good pallet to start pooling different colours of light around to really set off whatever coils and rods I dress this thing up with.  Really happy with how the ideas translating- I knew the red would likely wash out next to all these other brighter colours, so was hoping that it'd be protected mounted down in that tube, actually went just like I was thinking :).  And the green, yellow, Amber, and blue really do get nice splashes bouncing around the brass.  The largest tube is where the actual wire of the saber will run through and become part of the design in this chamber- figure it's time I made this huge mess of wiring work for me instead of against me all the time lol.  I just stuck some scrap wire in there so you could get idea.  Also you'll notice one smaller tube that's still empty- gonna make a coil that rises from that and works its way up toward the rest of the feature.
Quick shot of wiring- all this still needs to be disassembled so just kinda tacked in for time being.
(http://i736.photobucket.com/albums/xx2/major_major/5F372744-C1A1-466F-8F68-8B0D264841EA_zpsludkdovv.jpg) (http://s736.photobucket.com/user/major_major/media/5F372744-C1A1-466F-8F68-8B0D264841EA_zpsludkdovv.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/289C5D11-FF12-4720-9DAC-65EE522D8E94_zpsufbhlisw.jpg) (http://s736.photobucket.com/user/major_major/media/289C5D11-FF12-4720-9DAC-65EE522D8E94_zpsufbhlisw.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/FED0D6A6-7FAF-4989-8CE7-496AAE4B312D_zpsrpdz2be6.jpg) (http://s736.photobucket.com/user/major_major/media/FED0D6A6-7FAF-4989-8CE7-496AAE4B312D_zpsrpdz2be6.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/652FC6F0-AE8F-48A8-A0FC-20090BF02115_zpsmg4wzgfn.jpg) (http://s736.photobucket.com/user/major_major/media/652FC6F0-AE8F-48A8-A0FC-20090BF02115_zpsmg4wzgfn.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/37A24183-3845-44CF-B5AE-6FE035690133_zpsmopbkdhu.jpg) (http://s736.photobucket.com/user/major_major/media/37A24183-3845-44CF-B5AE-6FE035690133_zpsmopbkdhu.jpg.html)
Probably hard to tell in pics, but shows in person, I took a lot of time to make sure that everything went in on its own plane, vertically- so each light rises to a slightly different height, which helps create the effect I'm going for when lit up.
So like, I countersunk/ recessed some of these 3mm's in from the backside to diff depths, making sure the hole at the surface was big enough to let the sweet spot of the diode come through but not big enough for the little flange at the base of the diode, resulting in them protruding diff amounts. 
(http://i736.photobucket.com/albums/xx2/major_major/6F514729-8FF3-4C49-800C-83C01BD7FE39_zpskbbjfg9o.jpg) (http://s736.photobucket.com/user/major_major/media/6F514729-8FF3-4C49-800C-83C01BD7FE39_zpskbbjfg9o.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/A0221716-05F8-4249-8FB7-40D397F03117_zps11wef0ma.jpg) (http://s736.photobucket.com/user/major_major/media/A0221716-05F8-4249-8FB7-40D397F03117_zps11wef0ma.jpg.html)
So here you can see where I'll run the real wire up into the design (thanks for that idea Greg :) ), and that little empty tube will house the coil.

Aaaaannnd... (Even in brightly lit room) ... IT'S ALIVE HAHAHA!! ;).
(http://i736.photobucket.com/albums/xx2/major_major/D4B9798C-F883-4CD2-A722-2798D0782C76_zpsdpyahzqk.jpg) (http://s736.photobucket.com/user/major_major/media/D4B9798C-F883-4CD2-A722-2798D0782C76_zpsdpyahzqk.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/BF89A8E2-95EC-4BDB-9D19-895343BE4694_zpsehzxao60.jpg) (http://s736.photobucket.com/user/major_major/media/BF89A8E2-95EC-4BDB-9D19-895343BE4694_zpsehzxao60.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/DE2D5847-D86F-4F36-A8C5-478591C8A46E_zpsdqlf7cxh.jpg) (http://s736.photobucket.com/user/major_major/media/DE2D5847-D86F-4F36-A8C5-478591C8A46E_zpsdqlf7cxh.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/0BE8E406-AEDF-4B76-AE9A-AC5717901378_zpsoysy8nbd.jpg) (http://s736.photobucket.com/user/major_major/media/0BE8E406-AEDF-4B76-AE9A-AC5717901378_zpsoysy8nbd.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/3E3D44AD-48CA-44A1-A7A1-B7DB3313CBCF_zpsezpndpyr.jpg) (http://s736.photobucket.com/user/major_major/media/3E3D44AD-48CA-44A1-A7A1-B7DB3313CBCF_zpsezpndpyr.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/F573527F-86DC-4A97-978E-9390E779135D_zpsmhcgno7m.jpg) (http://s736.photobucket.com/user/major_major/media/F573527F-86DC-4A97-978E-9390E779135D_zpsmhcgno7m.jpg.html)
Still a million miles to go here lol- keep you posted- MTFBWY :).
And thanks again for kind words everyone! 

it's insane that everytime I come here it's just another giant level increase of awesome. Wow just wow!

How did I give you that wire idea?? LOL

Thanks so much hansrad!


Back when I was running the huge wire from act box you asked about it- I had considered it/ wanted to as well but was just too vulnerable there.  Here it's a no brainer since, where else am I gonna run wire if not inside hilt lol.  When I had the idea I thought 'ha, Greg will like this' lol. 

Super excited- the choke and latching AV i need are traveling towards me as I'm writing this, and i recently ordered a pommel i'll need, which I'm assuming will arrive with Ultra Saber's usual lightning speed, so soon i'll be able to move forward with the last aspects of this project!  I had been waiting till i actually had those parts because the areas I'm working in are so insanely small that i'll have to finish the designs and assemble the last features to fit the room that's actually there- which i can't know for sure till I've got it together in front of me.  I got a good start on these aspects, but its just too tight for me to finalize and then try to fit after the fact. 

i was gonna wait to show you guys this until i actually had it installed in those proper parts, so you could see how this will actually sit, but seeing as how its just around the corner now i think i can go ahead and post my early tinkering/ prep work/ test fitting- plus i just can't sit quiet on this any longer it's too awesome :).

now, first of all, as much as i'd like to lol i can't take any of the credit for this feature- that belongs 100% to one of our resident masters, JediXIX who recently shared an idea with me.  I would have never thought of this.  It was something he had been kicking around/ pondering but hadn't had a chance to actually use much in projects yet, that he knew would be right up my alley in general and just perfect for this project.  When he showed me what he was thinking my jaw hit the floor!  The idea was to take one of the cool blade plugs (the US one appeared most conducive to this) and mount an illuminated AV smack dab in the middle of it, then mount that whole thing in a vented pommel, and then backlight it with something.  Wicked, right?!  so here's one interpretation of this idea :).

now i didn't have a US plug handy- so i decided i'd test out the circle plug... what a nightmare lol!  though i will say, if you're willing to put in the work, i rather like how there's this little raised/ grooved ring left behind like a trim or bezel- looks good sitting behind the switch.  But man, what a pain- eventually had to switch to the dremel and burs and stones to remove the entire middle area of the plug (and the holes) and then just drill out what was left.  hitting it from the front was a no go- and even from the back those holes seemed exactly placed to give the 5/8" bit the hardest time lol.  It wasn't so much the thickness that made it challenging, but there's some question as to whether all the plugs are this thick, or whether some batches may be thinner- which might help?   

One thing to keep in mind- all this stuff you'll see is just thrown in loose because it's actually gonna end up in the incoming parts, so you might notice things sitting off centre etc in some pics, but only cause not mounted properly atm- just wanted to show you the basic formation of this feature and this sort of test fitting so can get basic idea.  So here's everybody's favourite circle plug as is, thrown in one of the only vented pommels i had handy- just as reminder what i started with.
(http://i736.photobucket.com/albums/xx2/major_major/001A164B-6142-458D-ADE1-D4D0528822F7_zpsc2bego9a.jpg) (http://s736.photobucket.com/user/major_major/media/001A164B-6142-458D-ADE1-D4D0528822F7_zpsc2bego9a.jpg.html)
... and after a few choice words lol.
(http://i736.photobucket.com/albums/xx2/major_major/FD1C1B33-8F08-4D5E-A3E1-D5FC7C527FF9_zpss6ex5iep.jpg) (http://s736.photobucket.com/user/major_major/media/FD1C1B33-8F08-4D5E-A3E1-D5FC7C527FF9_zpss6ex5iep.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/EBE10238-49BB-41E5-B88C-D809F601B8F0_zpsttzw1id3.jpg) (http://s736.photobucket.com/user/major_major/media/EBE10238-49BB-41E5-B88C-D809F601B8F0_zpsttzw1id3.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/89618B64-EB64-4EF7-8C2B-F81FCE5F906A_zpsxjubjmbi.jpg) (http://s736.photobucket.com/user/major_major/media/89618B64-EB64-4EF7-8C2B-F81FCE5F906A_zpsxjubjmbi.jpg.html)

So, if you've ever looked really closely at a 5mm led before (i hadn't really before this) you'll notice they have a little flat spot in the thin flange at the base of their lens, above the cathode.  So if you make holes with little notches in the bottom of them like this, you can actually seat the led's inside the wall of the poly carb tube flush- they won't exceed the profile of the plug and so it will still clear a 1" ID :). 

(http://i736.photobucket.com/albums/xx2/major_major/951B033F-F0A8-46D7-A78E-F69DD03ADFC7_zpsjuqa79zt.jpg) (http://s736.photobucket.com/user/major_major/media/951B033F-F0A8-46D7-A78E-F69DD03ADFC7_zpsjuqa79zt.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/8F0B295F-8AC9-4D2A-B391-AA8C614C729A_zpsztcfngld.jpg) (http://s736.photobucket.com/user/major_major/media/8F0B295F-8AC9-4D2A-B391-AA8C614C729A_zpsztcfngld.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/71871D21-82E8-4CB6-8EA7-77B2C34DB12F_zpslsoofubn.jpg) (http://s736.photobucket.com/user/major_major/media/71871D21-82E8-4CB6-8EA7-77B2C34DB12F_zpslsoofubn.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/A670F5C3-26F5-4AF2-AE63-38236FC01819_zpsyw7xl8zs.jpg) (http://s736.photobucket.com/user/major_major/media/A670F5C3-26F5-4AF2-AE63-38236FC01819_zpsyw7xl8zs.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/50F61696-5DC5-48EC-B56C-3328C3786112_zpssaphsz8v.jpg) (http://s736.photobucket.com/user/major_major/media/50F61696-5DC5-48EC-B56C-3328C3786112_zpssaphsz8v.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/CE8EDBD6-EDC4-4FDD-B7EA-B1FD711EBBCB_zpswnhyd9xk.jpg) (http://s736.photobucket.com/user/major_major/media/CE8EDBD6-EDC4-4FDD-B7EA-B1FD711EBBCB_zpswnhyd9xk.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/2B18F4EA-15EF-4B43-86D4-1603639100FA_zpswh93hvwi.jpg) (http://s736.photobucket.com/user/major_major/media/2B18F4EA-15EF-4B43-86D4-1603639100FA_zpswh93hvwi.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/FE69C094-921C-4682-994E-D89EC6C6C24A_zpskeciz51k.jpg) (http://s736.photobucket.com/user/major_major/media/FE69C094-921C-4682-994E-D89EC6C6C24A_zpskeciz51k.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/D7552E00-0C73-42BB-A423-514078A8D8E3_zpspl5f1k1r.jpg) (http://s736.photobucket.com/user/major_major/media/D7552E00-0C73-42BB-A423-514078A8D8E3_zpspl5f1k1r.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/858AF907-D24E-47DA-89DF-BD703228A946_zpswxk9e1h6.jpg) (http://s736.photobucket.com/user/major_major/media/858AF907-D24E-47DA-89DF-BD703228A946_zpswxk9e1h6.jpg.html)

ok, now the only illuminated switches i had at time were momentary, which didn't matter at all for testing since only wring up it's led, but the only red ones i had were dots, and the actual switch i'll be using is a red ring illuminated black latching AV, so i figured i'd get best sense of the look by going with a yellow ring i had in testing.  if this were a jedi saber i'd probably leave it at this here, especially if was yellow or green bladed- but since this sith saber's gonna have a red switch all day long, its a good thing that the whole point of ALL that stuff was merely to get a pattern of variation in the colour of the backlighting... so that when i add the real horse power of illumination, it goes like this (well, something like this, i'll def tweak/optimize it when i mount the real deal):
(http://i736.photobucket.com/albums/xx2/major_major/10B7376E-22D2-43C1-8D23-9D23350D7135_zpsini8omty.jpg) (http://s736.photobucket.com/user/major_major/media/10B7376E-22D2-43C1-8D23-9D23350D7135_zpsini8omty.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/C8695BF0-89F4-4CAC-93C1-D9A73CDCB100_zpsebii1dcz.jpg) (http://s736.photobucket.com/user/major_major/media/C8695BF0-89F4-4CAC-93C1-D9A73CDCB100_zpsebii1dcz.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/5770B157-2A09-4B23-9AC6-A696A0F8B0EB_zpskv3hrktr.jpg) (http://s736.photobucket.com/user/major_major/media/5770B157-2A09-4B23-9AC6-A696A0F8B0EB_zpskv3hrktr.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/0937FA79-66D2-4ECE-B70D-156552B50C05_zpsot2zgvpj.jpg) (http://s736.photobucket.com/user/major_major/media/0937FA79-66D2-4ECE-B70D-156552B50C05_zpsot2zgvpj.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/6D2A8856-2764-40AA-ABEA-9A22C2C63BCE_zpseimbyjn5.jpg) (http://s736.photobucket.com/user/major_major/media/6D2A8856-2764-40AA-ABEA-9A22C2C63BCE_zpseimbyjn5.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/62935E78-A1A2-4333-B0E3-B2B66B2C890B_zpsorkjpp4d.jpg) (http://s736.photobucket.com/user/major_major/media/62935E78-A1A2-4333-B0E3-B2B66B2C890B_zpsorkjpp4d.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/39642978-1B63-4EFE-AE33-C653744AFAB1_zpsvuxzsunh.jpg) (http://s736.photobucket.com/user/major_major/media/39642978-1B63-4EFE-AE33-C653744AFAB1_zpsvuxzsunh.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/3DAE9B8D-5630-4D75-B144-79FAA70C09F4_zpsrldj6bud.jpg) (http://s736.photobucket.com/user/major_major/media/3DAE9B8D-5630-4D75-B144-79FAA70C09F4_zpsrldj6bud.jpg.html)
It is gonna be seriously challenging fitting this all in, but i can't wait!  Also can't wait to finalize the look of the chamber with recharge port and kill key for switching to display mode.  Ive wanted to get into that kind of thing for a while now so pretty pumped- Thanks again to Jed for sharing this wicked idea!  keep you posted, MTFBWY :).   

I'm enjoying how this has basically become one big project to try and fit every single construction idea ever into one hilt. It's like the Frankenstein's Monster of sabers, and it's glorious.

Awesome, Rev! That is a super cool feature! Props to Jed for coming up with it and to you for implementing it so beautifully.

Glad you're up to the challenge of fitting all that in, because it looks like it will be interesting  :D

Thanks Kouri :).

yyyep, lol, and i think i even threw in the "It's alive!!" line somewhere back there hahaha!  For a stunt, this is gonna be one sexy freakish beast lol- I think if there was gonna be a lightsaber in that one season of american horror story, you guys know which one i mean right, with the carnival people?, this would have been that saber lol.

Thanks Sedsti!  Appreciate :).  O man, theres gonna be some tense moments to say the least lol.  But i'll be able to trim the plug down a bit at least, the led legs, and a lot of the excess wiring there once its in the right vented pommel and attached to choke/ reveal.  Still gonna need all the luck there is lol.   

Holy cow man! Thats an amazing addition. You may need to consider an alternative way to access the board. Like a hatch or shroud. That way you can lay down your wiring and not have to worry about kram-fu and having extra wire to pull your chassis out. My latest venture barely accommodated a jst for the battery. Still trying to wrap my brain around a shroud build with built in board. Point for the addition. Great execution.

Wicked cool,  idea XIX  and execution  Revan, this is without a doubt a very slick placement, perfect solution for the combat user, as well you already said can be for sound too just make some cut out vents boom, i wouldn't be surprised if someone picks this up as an option  ;D + a few for ya's both

I'm very proud, my young apprentice, hehe . . .  ;)  A few points coming your way  ;D

Seriously outstanding work here Rev, and to be fair it was your idea to mount the LEDs in the plug wall, and I'll borrow that idea for sure one day . . . As Bulvoy has said before, this is one of the reasons this place is so awesome, we all share our ideas, and its fun and inspiring seeing what we all do, I'm really proud to be part of this community with all the super talented people here . . .


Of course mounting a switch in the pommel is not a new idea, but doing that can cause problems with twisted wires and such . . . doing this with the blade plug allows us to screw on the pommel while keeping the wiring in place then secure the plug with a retention screw in the pommel . . . and the lighting effect is a cool added bonus . . .

Lowering the switch / blade plug in the pommel (like this pic) will keep it protected and out of the way . . . this also looks very cool . . . can't wait to see all this put together in your project . . .  8)

Thanks so much everyone for the input and kind words- it's an honour :).  Sorry I've been awol latley - insanely busy the last few weeks.  But I'll catch up on everyones posts etc soon.  EVERYTHING I need is now sitting on my bench!  US had my vented pommels here unbelievably fast :).  I got the choke here a lot faster by skipping the black powder coating I had originally planned (my call, no complaints :) ), and with it came the latching AV! Gonna be doing so much to choke i might as well do the colouring myself anyway.   
Prob doesn't look much diff in pics but in person it's a beautiful deep red, looks awesome- and i really like the way the black switch looks with this circle plug- goes well with the patterns etc. 
(http://i736.photobucket.com/albums/xx2/major_major/EDB43C59-F1F7-49AD-93F4-3CAC70B8FD69_zpstknuopkz.jpg) (http://s736.photobucket.com/user/major_major/media/EDB43C59-F1F7-49AD-93F4-3CAC70B8FD69_zpstknuopkz.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/A56DBEA5-DAE7-4258-91A3-1F180F33E689_zps430t3yqv.jpg) (http://s736.photobucket.com/user/major_major/media/A56DBEA5-DAE7-4258-91A3-1F180F33E689_zps430t3yqv.jpg.html)
It'll be centred etc.  I'm thinking that I'll have to have it sitting a bit more flush due to space limitations, as you'll see lol, but I know I'll be able to recess it at least a little like in these pics.

So remember how I kept going on and on about how I needed to wait till the parts got here before I got too carried away building things lol?  Hahaha, epic fail, the ID of the area that will house this little chassis is not just a little smaller than what I guessed, it's like half the size lol!...  So guess who gets to scrap that whole thing and redo a much smaller, much more challenging version lol?!   yep, lol, round two!  No worries, I know for sure everything I wanted to do I'll still accomplish- everything will fit, I know it :), but It does mean this is going to be WAY more difficult than it already was lol, and prob gonna take a bit longer.  Basically means it's gonna go like this from this point on, I'll prob end up having to do a few versions of everything before I get it just right is all. 
The area I've got is bigger than 3/4", smaller than 7/8"- looks like I'll have about 1.5" worth of free space give or take lol!  But I swear it can be done.
(http://i736.photobucket.com/albums/xx2/major_major/8FADCEC1-B2EF-4861-8809-EBFA893039E7_zps8etwsa4m.jpg) (http://s736.photobucket.com/user/major_major/media/8FADCEC1-B2EF-4861-8809-EBFA893039E7_zps8etwsa4m.jpg.html)
Theres one more hole in the centre where I'll need to run a couple wires through, which is why those knurl nuts/ fittings have the little notches taken out of bottom, so when they line up they form a little through way for wire.  You can see I notched out a couple of the tubes to get around the nuts, and squished and bent one a bit for the same reason.  This base is way smaller, so this entire feature just became a lot trickier lol.  But I actually managed to fit more in this one, go figure :).  Here was the prepping for mark 2... Actually everything's getting reprepped because it's all gotta go in like a rubix cube. 
(http://i736.photobucket.com/albums/xx2/major_major/04BFF3DD-0AD4-4148-B919-CF1D1CEF6CFC_zps0yrzshaq.jpg) (http://s736.photobucket.com/user/major_major/media/04BFF3DD-0AD4-4148-B919-CF1D1CEF6CFC_zps0yrzshaq.jpg.html)
Everything you see there ends up in this thing- and one thing you don't lol, my recharge port is up on the blue parts bin,  I just needed a place to work.
New and old for comparison... O why couldn't you have been that big lol!?
(http://i736.photobucket.com/albums/xx2/major_major/9FD8299F-3424-4A20-9700-6D059CC41EA0_zpsvgujhzef.jpg) (http://s736.photobucket.com/user/major_major/media/9FD8299F-3424-4A20-9700-6D059CC41EA0_zpsvgujhzef.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/6AAD4633-8BE7-488C-8F7E-0DEF1CF4A617_zpsnb2vwzhx.jpg) (http://s736.photobucket.com/user/major_major/media/6AAD4633-8BE7-488C-8F7E-0DEF1CF4A617_zpsnb2vwzhx.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/CE5E8153-239E-43FA-B7DD-45B1CF9A0230_zpsdslcs37l.jpg) (http://s736.photobucket.com/user/major_major/media/CE5E8153-239E-43FA-B7DD-45B1CF9A0230_zpsdslcs37l.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/AE1EACC9-E8FD-45F3-883B-B8ACEE25C550_zpsr4b91puu.jpg) (http://s736.photobucket.com/user/major_major/media/AE1EACC9-E8FD-45F3-883B-B8ACEE25C550_zpsr4b91puu.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/15658891-4962-46BD-B363-208DF383C0D9_zpsxbbdqotw.jpg) (http://s736.photobucket.com/user/major_major/media/15658891-4962-46BD-B363-208DF383C0D9_zpsxbbdqotw.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/D3ECC9ED-4561-4C31-ABFB-170FC5909575_zpsluframxr.jpg) (http://s736.photobucket.com/user/major_major/media/D3ECC9ED-4561-4C31-ABFB-170FC5909575_zpsluframxr.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/847ABBD5-FE99-47F7-AC87-B9528BF86337_zps9boztufs.jpg) (http://s736.photobucket.com/user/major_major/media/847ABBD5-FE99-47F7-AC87-B9528BF86337_zps9boztufs.jpg.html)
Some of these pics are before was wired or finished cutting even, but here you can at least see how will sit.  This is in such an early stage of work that in the rest of the pics you prob won't be able to tell how it's actually going to look etc.  This isn't even close to how the wire will run, I basically just used it to help hold everything together lol since all sitting in so loose (that and tape lol)- that's why stuff looks like leaning or off centre in some pics.  Though I will be including some resistors and wire in the design, and prob will be wrapping some wire up the tubes, but smaller wire to feed the switch lights, and done differently-  I still need to fit the kill key and USB recharge port/ adapter too so just waiting to see how best to incorporate. 
(http://i736.photobucket.com/albums/xx2/major_major/2F0D3F98-F15C-4532-A17E-378A27FFC7E4_zpsqf3l6iw6.jpg) (http://s736.photobucket.com/user/major_major/media/2F0D3F98-F15C-4532-A17E-378A27FFC7E4_zpsqf3l6iw6.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/2F0D3F98-F15C-4532-A17E-378A27FFC7E4_zpsqf3l6iw6.jpg) (http://s736.photobucket.com/user/major_major/media/2F0D3F98-F15C-4532-A17E-378A27FFC7E4_zpsqf3l6iw6.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/9EAFD5A4-D0C4-4A8B-8FB9-A6BD43B4BC96_zpsxl8iseq0.jpg) (http://s736.photobucket.com/user/major_major/media/9EAFD5A4-D0C4-4A8B-8FB9-A6BD43B4BC96_zpsxl8iseq0.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/707FA116-4249-433F-9DE3-682A745D809C_zpsxzwqz0o5.jpg) (http://s736.photobucket.com/user/major_major/media/707FA116-4249-433F-9DE3-682A745D809C_zpsxzwqz0o5.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/450304AB-A9A4-4857-9A41-D29D030B475A_zpsim4somau.jpg) (http://s736.photobucket.com/user/major_major/media/450304AB-A9A4-4857-9A41-D29D030B475A_zpsim4somau.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/05237EDB-ACD2-4A39-8506-DF7335A26286_zpsj5402lyj.jpg) (http://s736.photobucket.com/user/major_major/media/05237EDB-ACD2-4A39-8506-DF7335A26286_zpsj5402lyj.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/1DE95D19-2A1D-4F3F-95D2-3AE68CFFE076_zpshir6rnxn.jpg) (http://s736.photobucket.com/user/major_major/media/1DE95D19-2A1D-4F3F-95D2-3AE68CFFE076_zpshir6rnxn.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/7E56C75C-8EB1-452A-AB90-6FBDEB8A8384_zpslw2umddd.jpg) (http://s736.photobucket.com/user/major_major/media/7E56C75C-8EB1-452A-AB90-6FBDEB8A8384_zpslw2umddd.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/12B75A3E-D2A4-41DA-838C-A083EF137F7E_zpsgkauxfqj.jpg) (http://s736.photobucket.com/user/major_major/media/12B75A3E-D2A4-41DA-838C-A083EF137F7E_zpsgkauxfqj.jpg.html)
... Yep, that's all going in there lol!  But I've got a few tricks up my sleeve ;).  I'll be able to ditch a couple resistors once these two cricuits are combined, plus, with the exception of what will be incorporated into chamber, I'm ditching pretty much every wire you see and replacing it with a little 3/8" stub of wire, and every single connection you see will be reduced/ combined into just two, one positive pad and one negative on a little circuit board mounted between these two features, with all the little stubs of wire doing tiny straight shots to where they go, resistor legs hooked right to accent posts wherever possible, etc- not to mention cutting the blade plug down to the length of the latching AV. 


 

Thanks for that update Rev! +1 ofcourse. Work of art!

RevanReborn . . . . "kram-fu" Master  ;) . . . . more points  8)

Thanks guys :).  Slow going on the external half of the chassis- but totally happy with how its turning out.  Not my finest hour in terms of dremel slips and scratches, but considering I'm gonna be cutting this whole thing in half, right through the centre of the choke, then sanding the crap out of it and painting it, plus possibly still engraving it and a couple other little additions lol, i know none of this butchery will show lol :).  I know its look'n a bit rough at the moment, but you can trust me on this one lol, its gonna turn out awesome- theres just a bit too much going on in this vision to really describe it all in a way you could visualize just yet- soon enough you'll actually be able to see what i mean though.  It's just SUCH a tiny area, tad less than an inch, SO hard to chew through the areas you need gone without touching the areas you don't lol.  But luckily all the damage is super shallow and in spots where it gets covered up.  Actually i gotta say, i wasn't exactly sure that this would turn out, so I'm stoked that its gonna work.   

the inner portion of the chassis was just too narrow of a support base now that its been shrunk down to a smaller version.  It'd be too wobbly when the telescoping rods were pulled down/ out- this way will give a wider support structure and smoother/ sturdier telescoping action, plus it's just gonna look sick on the hilt when done- you'll actually see two of the brass rods running down in the choke- totally suits this bad boy!  Lining them up to be on what i'd consider the sides of the hilt, lined up with the activation box on one side and the exposed circuit on the other. this will leave open sides for viewing/ access and also for mounting the locking/ securing mechanisms.  Since i don't want this reveal style access chamber just sliding open on me, ill be rigging up a way to lock it closed.   Also, i'm making the outer tubes that the rods slide in have little notches/ windows at the top so that i'll be able to see when the rods are nearing the end of their track so to speak, so i'll be able to avoid accidentally pulling the chassis all the way out (removing) when i don't want to. 

Can't overstate how challenging this is gonna be to both create the decorative aspects of the chassis and mount it all in along with the functional aspects of it, in such a tiny space.  Hard to explain, but all the way along lining things up and cutting things in etc. will entail assembling things, then disassembling things, over and over and over again lol, working on the tiniest little bits and then test fitting again, and just fighting for every little molecule of space while doing the work in a very careful, very specific order.  in such tight quarters you have to think very carefully about how everything fits together, hows it's going to be installed, and how it will be able to be removed, and this totally determines the best order to start tackling things if you know what i mean- like for instance, these rods are fitted perfectly for their places, but even still, and even with the perfect nest carved right out of the aluminum for them, the fit in this section is just SO surgical that you can't just thread the extension/ choke onto the body and then expect to slide the tubes/ rods into their sockets.  The chassis bases and support structures inside the body are all mounted in with each other so close that there isn't even enough room for the tubes to enter and straighten out/ achieve an angle that allows them to enter their sockets. the upper chassis base will have to be completed and installed right into the top of this choke itself, flush or even a little higher than the top of the threads, and then this entire piece can be threaded on nice and smooth.  This means that i'll actually have to get all the internals from the illuminated/ dressed up power bank and above (basically the whole saber above this choke) installed, then run the leads out the bottom and though the top half of this chamber/ choke piece once its completed, so that i'll be able to tie into the the wiring of everything down in the bottom. 

Probably just all sounds like a confusing mess lol, but you'll see what i mean soon!  Once i get done cutting these structural elements in, which takes forever to align etc, i'll be able to show you what a rubix cube this is hahaha :). 
(http://i736.photobucket.com/albums/xx2/major_major/893530F0-FFDE-4B43-A5AF-ADB0A3C0B4DE_zpsvqy6mydi.jpg) (http://s736.photobucket.com/user/major_major/media/893530F0-FFDE-4B43-A5AF-ADB0A3C0B4DE_zpsvqy6mydi.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/049C6E23-74B8-47AA-9323-D0CFC0E095EC_zpsygzjii9x.jpg) (http://s736.photobucket.com/user/major_major/media/049C6E23-74B8-47AA-9323-D0CFC0E095EC_zpsygzjii9x.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/F083EFC6-4AAD-40A4-A7FE-2F0AF283D07D_zpsd3id3erg.jpg) (http://s736.photobucket.com/user/major_major/media/F083EFC6-4AAD-40A4-A7FE-2F0AF283D07D_zpsd3id3erg.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/645AED6D-D2F4-4BAB-A59A-6ECABB4A045B_zpsrplx3rzh.jpg) (http://s736.photobucket.com/user/major_major/media/645AED6D-D2F4-4BAB-A59A-6ECABB4A045B_zpsrplx3rzh.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/42F6B248-325C-49B7-9116-B5A118217E5E_zpsq8b4fmaj.jpg) (http://s736.photobucket.com/user/major_major/media/42F6B248-325C-49B7-9116-B5A118217E5E_zpsq8b4fmaj.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/24AB2479-4BB6-4DBA-A851-95B48323FE2B_zpsi3vwlecd.jpg) (http://s736.photobucket.com/user/major_major/media/24AB2479-4BB6-4DBA-A851-95B48323FE2B_zpsi3vwlecd.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/38CBCFA4-595B-424B-A810-AD592433E30A_zpsltc0f0lc.jpg) (http://s736.photobucket.com/user/major_major/media/38CBCFA4-595B-424B-A810-AD592433E30A_zpsltc0f0lc.jpg.html)

really excited about the way this will tie into the look of the overall hilt- if you remember there's a brass bezel around the accent in the front of the hilt (old switch location), there's the gold of the exposed circuit, the little brass greeblies on the activation box, and now a splash of brass down at the bottom of the hilt as well :).  It's gonna be a frankenstein, but a well proportioned, evenly distributed one lol!  Keep you posted, MTFBWY.

nod. Hell yea!

Geez, this project goes deep into the forest!
Looks really good!

Thanks guys!  Appreciate, big time :).

I know right, Medwyn hahaha?!  It's like it just keeps going and going lol!  But believe it or not, the end is actually in sight now- so pumped :).  Got some really challenging work in front of me but there'll be no stopping me now :).  Can't wait till I can show everyone all these features at home in the completed hilt! 

Other side's outer telescoping rods banged out :).  Next step space out the holes in the upper base and design/ assemble the upper half of chassis.  Might notice what looks like notches at the top of those brass tubes- those are little windows so I can see when inner rods (not inserted in pics) are nearing the end of their track.
(http://i736.photobucket.com/albums/xx2/major_major/6370B995-3E55-4CC7-A99C-87331A626018_zpsehubbcnd.jpg) (http://s736.photobucket.com/user/major_major/media/6370B995-3E55-4CC7-A99C-87331A626018_zpsehubbcnd.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/4DCCCBF6-42D8-4F80-87EB-B944EDCDA04B_zpsrwdwgi1e.jpg) (http://s736.photobucket.com/user/major_major/media/4DCCCBF6-42D8-4F80-87EB-B944EDCDA04B_zpsrwdwgi1e.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/8859C48C-AA50-46EB-B142-0B6F74A5A4A6_zpsqsiuxjsd.jpg) (http://s736.photobucket.com/user/major_major/media/8859C48C-AA50-46EB-B142-0B6F74A5A4A6_zpsqsiuxjsd.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/CD906FEC-9CD9-454E-954E-E3135AED2C80_zpsp1ntpzhq.jpg) (http://s736.photobucket.com/user/major_major/media/CD906FEC-9CD9-454E-954E-E3135AED2C80_zpsp1ntpzhq.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/CF35E128-B9A3-4FCA-A430-10CD174C99FF_zpspkaxaydf.jpg) (http://s736.photobucket.com/user/major_major/media/CF35E128-B9A3-4FCA-A430-10CD174C99FF_zpspkaxaydf.jpg.html)
Keep you posted :).

Sorry, but all those shots were focused on showing the area- I didn't like any of the full body shots, didn't give clear enough look at what the whole profile of this saber is with this extension etc:
I'm really loving the slightly elongated bottom end now- proportioned more like a graflex this way- it's significantly larger than one, but I mean the proportions of the sections match that now.
(http://i736.photobucket.com/albums/xx2/major_major/22AE4966-0F80-4900-9705-79BDDCEB9613_zpsrrjfxzaj.jpg) (http://s736.photobucket.com/user/major_major/media/22AE4966-0F80-4900-9705-79BDDCEB9613_zpsrrjfxzaj.jpg.html)
Getting excited!
This update brought to you by Darth Arlo- for whom nothing is EVER good enough lol.
(http://i736.photobucket.com/albums/xx2/major_major/12D63E15-DB98-403C-84BE-B568E8A0BFCA_zps5tvbbf4z.jpg) (http://s736.photobucket.com/user/major_major/media/12D63E15-DB98-403C-84BE-B568E8A0BFCA_zps5tvbbf4z.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/88C7121A-7079-4953-8330-C5999CE892E6_zps1lyykkdi.jpg) (http://s736.photobucket.com/user/major_major/media/88C7121A-7079-4953-8330-C5999CE892E6_zps1lyykkdi.jpg.html)

Bravo.. Looks Fantastic. The pup is right by the by, lol

Epic RevanReborn!


Sent from my iPhone using Tapatalk

Thanks GQ :).

So I'm def gonna be able to recess the plug/ switch a bit :).  In these pics the switch itself is pushed out of plug a bit from the wire jammed up inside it but will be seated flush on the plug, which can actually be fit up inside, so a win there.  If you look close you can see how switch came out a bit in pics.
(http://i736.photobucket.com/albums/xx2/major_major/2A7481F4-21C6-4B9F-9006-A0FA11E7F474_zpszcqbhfxp.jpg) (http://s736.photobucket.com/user/major_major/media/2A7481F4-21C6-4B9F-9006-A0FA11E7F474_zpszcqbhfxp.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/02E06FA3-FD2C-4729-9EE0-2DFB99FC0A07_zpsfpjh8vt5.jpg) (http://s736.photobucket.com/user/major_major/media/02E06FA3-FD2C-4729-9EE0-2DFB99FC0A07_zpsfpjh8vt5.jpg.html)
Here you can see what i mean about the wider/ sturdier base of support the chassis has now.  Of course, a lot of the rods/ tubes that stick up past the threads of the choke will be removed, only about a 1/4" sticks up above.
(http://i736.photobucket.com/albums/xx2/major_major/40C43194-37B8-43D6-A5D4-DEAC0A52CBCE_zpsorwjzugj.jpg) (http://s736.photobucket.com/user/major_major/media/40C43194-37B8-43D6-A5D4-DEAC0A52CBCE_zpsorwjzugj.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/DA47B28C-99CA-4ABE-AE50-862ABA0BAA16_zpsvvebottu.jpg) (http://s736.photobucket.com/user/major_major/media/DA47B28C-99CA-4ABE-AE50-862ABA0BAA16_zpsvvebottu.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/537B2BF6-4E60-4FBC-A487-F62B1CF6A945_zpsqpdvfb0z.jpg) (http://s736.photobucket.com/user/major_major/media/537B2BF6-4E60-4FBC-A487-F62B1CF6A945_zpsqpdvfb0z.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/344E016E-FCCF-43D4-9481-B144967C82C3_zpsfk4un0rq.jpg) (http://s736.photobucket.com/user/major_major/media/344E016E-FCCF-43D4-9481-B144967C82C3_zpsfk4un0rq.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/102BFB6A-3830-4754-B20C-D6EB57A4C85F_zpsh1qugnzs.jpg) (http://s736.photobucket.com/user/major_major/media/102BFB6A-3830-4754-B20C-D6EB57A4C85F_zpsh1qugnzs.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/BD3391CC-039E-4AAC-962B-95029D9C8329_zps0rp5aovk.jpg) (http://s736.photobucket.com/user/major_major/media/BD3391CC-039E-4AAC-962B-95029D9C8329_zps0rp5aovk.jpg.html)
I still have to wait till further along to show you how it all fits together, but that gap lines up with where the threads for the choke and vented pommel come together.  A piece of circuit board will lock into place between those parts with everything run to it.  The plug is trimmed to length and now has more notches to help the accent legs fit in, and two deep channels cut into the other sides (can't really see here), to allow the rods to slide through the edges so the chassis can operate.  You can just picture how they will look with the switch wires and all the 5mm led's and resistors all in that 1" space HAHAHAHA!  It's like there won't even be air, just solid packed.  Even with the circuit board trick, I'll likely have to carve some more contours into the inside of the plug for the resistors.

Alignment
(http://i736.photobucket.com/albums/xx2/major_major/71517165-7565-4F49-92D6-EBFE59903AE6_zpscp0ggsk2.jpg) (http://s736.photobucket.com/user/major_major/media/71517165-7565-4F49-92D6-EBFE59903AE6_zpscp0ggsk2.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/2C658023-61E3-4D15-B1CD-6A63B89F5814_zpspzk1xfk5.jpg) (http://s736.photobucket.com/user/major_major/media/2C658023-61E3-4D15-B1CD-6A63B89F5814_zpspzk1xfk5.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/10EEF934-EA18-45DE-84E1-A8CC7BA8BFBD_zpswwvkrmvc.jpg) (http://s736.photobucket.com/user/major_major/media/10EEF934-EA18-45DE-84E1-A8CC7BA8BFBD_zpswwvkrmvc.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/F85A3AB8-E657-4F63-A665-CA6AAF429424_zps6r3fb23k.jpg) (http://s736.photobucket.com/user/major_major/media/F85A3AB8-E657-4F63-A665-CA6AAF429424_zps6r3fb23k.jpg.html)
Keep you posted :), MTFBWY.  Thoughts are with everyone affected by the tragedy in Florida.

More progress here than looks like lol.  Since its just dropped in loose the chassis kept collapsing every time I'd set it up for pics, so I had to wrap a couple little pieces of tape around the spot where the tubes go into eachother just to hold it up to take photo.  I haven't made the holes in the upper base for the outer most rods, so it won't quite close all the way, but you'll get the idea here.
(http://i736.photobucket.com/albums/xx2/major_major/7E93B76B-D0D4-4721-AEAB-E343B30F76C1_zpseculbrzt.jpg) (http://s736.photobucket.com/user/major_major/media/7E93B76B-D0D4-4721-AEAB-E343B30F76C1_zpseculbrzt.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/C063894F-02DF-4A10-B9DE-EAB94E8445D0_zps6f54p52q.jpg) (http://s736.photobucket.com/user/major_major/media/C063894F-02DF-4A10-B9DE-EAB94E8445D0_zps6f54p52q.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/6303EF44-D90A-42FE-804D-AB5A2FEE0A89_zpsklaytlgk.jpg) (http://s736.photobucket.com/user/major_major/media/6303EF44-D90A-42FE-804D-AB5A2FEE0A89_zpsklaytlgk.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/4CDC23F2-1248-40F8-8AA0-3953D7793CB6_zpsqfgy3div.jpg) (http://s736.photobucket.com/user/major_major/media/4CDC23F2-1248-40F8-8AA0-3953D7793CB6_zpsqfgy3div.jpg.html)
You won't see the upper base directly- this is just the mechanism that will allow everything (below the cut through the centre of the choke) to be slid down/ out.
(http://i736.photobucket.com/albums/xx2/major_major/B4CC8067-9682-4AA6-8EFC-9FBA0E426769_zpskcufwff2.jpg) (http://s736.photobucket.com/user/major_major/media/B4CC8067-9682-4AA6-8EFC-9FBA0E426769_zpskcufwff2.jpg.html)
Can see now exactly how much I'll be able to recess switch... Not much lol- but there's just no more room- I'm keeping track of my space in 32nd's and 64th's in there lol.
(http://i736.photobucket.com/albums/xx2/major_major/C2A87971-40E0-4D29-B36F-23D001B0D244_zpspyuwyxcv.jpg) (http://s736.photobucket.com/user/major_major/media/C2A87971-40E0-4D29-B36F-23D001B0D244_zpspyuwyxcv.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/B1C7626F-9B9E-4B2D-B946-01519B5165E0_zpsvfeqpiei.jpg) (http://s736.photobucket.com/user/major_major/media/B1C7626F-9B9E-4B2D-B946-01519B5165E0_zpsvfeqpiei.jpg.html)
And this is how I plan to actually make this work hahaha!  
(http://i736.photobucket.com/albums/xx2/major_major/06E87826-39CE-4AF6-976D-92D301860A7A_zpsc3itryu5.jpg) (http://s736.photobucket.com/user/major_major/media/06E87826-39CE-4AF6-976D-92D301860A7A_zpsc3itryu5.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/C247AB74-7662-43BE-BAF1-785A833C0894_zpswnggqf0m.jpg) (http://s736.photobucket.com/user/major_major/media/C247AB74-7662-43BE-BAF1-785A833C0894_zpswnggqf0m.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/76360AD8-B3B6-457F-98E4-5E9366A574C3_zpsypu07esj.jpg) (http://s736.photobucket.com/user/major_major/media/76360AD8-B3B6-457F-98E4-5E9366A574C3_zpsypu07esj.jpg.html)
So, if you see how this stuff gets packed in, starting from the outside and working our way in, it goes- from the aluminum inner wall of hilt, to a little microscopic gap for the 5mm accent negative legs and their wire, then there's the layer of blade plug with the 5mm's in it, then there's a gap with the 5mm positive legs and their wire in it, then there's the AV core.  All butted right up against the circuit board, with the bottom chassis base butted up against that on the other side- everything running to the two pads on the board with only the positive, negative, and the switch wires needing to run up and join the rest of the internals.
(http://i736.photobucket.com/albums/xx2/major_major/00D63D89-6214-466A-AB35-BD4D7AA3064E_zpsoxboywqn.jpg) (http://s736.photobucket.com/user/major_major/media/00D63D89-6214-466A-AB35-BD4D7AA3064E_zpsoxboywqn.jpg.html)
Won't actually seat all the way down until I make the holes for those outer rods.
(http://i736.photobucket.com/albums/xx2/major_major/A3A2A422-FC81-4004-820A-493F513A4417_zpsnqxba4lq.jpg) (http://s736.photobucket.com/user/major_major/media/A3A2A422-FC81-4004-820A-493F513A4417_zpsnqxba4lq.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/103F86E2-D666-4946-B9CE-C7D77B11ADAE_zpsqsinvj7j.jpg) (http://s736.photobucket.com/user/major_major/media/103F86E2-D666-4946-B9CE-C7D77B11ADAE_zpsqsinvj7j.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/F69F71D7-E132-49D2-8F98-FCB7A060D2DB_zpsrnen0kbb.jpg) (http://s736.photobucket.com/user/major_major/media/F69F71D7-E132-49D2-8F98-FCB7A060D2DB_zpsrnen0kbb.jpg.html)
I'm very close to being able to make that cut through the choke- and once that's done- this part will really start to take shape :).  Keep you posted, MTFBWY.

This thing is looking quite hefty, Rev! With you're cramming skills, you might as well make this a double bladed saber at this point  ;)

HAHAHAHA!  Whoa whoa whoa Sedsti, let's not get carried away here ;) lol, I think that might wreck the sort of minimalist charm I was going for on this one... (Rev tries to keep straight face and fails) hahaha! 

Thanks buddy :). 

Ah!  bummer, i thought i already posted some of this last night!  been doing that a lot lately lol.  Got the holes notched out of the upper chassis base for the outer most rods, so that meant time to go make that cut through the choke.  Once that's done i can finish cutting in the rest of the components in the upper chassis base and then begin the final assembly of the whole piece.  (http://i736.photobucket.com/albums/xx2/major_major/F82D196C-D63F-4FB0-A065-4DE2723AB7D2_zps4e8wucxy.jpg) (http://s736.photobucket.com/user/major_major/media/F82D196C-D63F-4FB0-A065-4DE2723AB7D2_zps4e8wucxy.jpg.html)
That's right about where it will sit when installed too.  pushed up absolutely as far as it can go until it buts into the bottom of the power bank, to give me as much room as possible to work with down in the incredibly small/ confined space of the 'chamber' for the usb recharge and kill key.  (http://i736.photobucket.com/albums/xx2/major_major/55315217-0992-4B01-8F76-2C144AF70952_zpshyklf5ht.jpg) (http://s736.photobucket.com/user/major_major/media/55315217-0992-4B01-8F76-2C144AF70952_zpshyklf5ht.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/F52A49C7-4616-4C96-AA9A-620D453096DA_zps37jm2l13.jpg) (http://s736.photobucket.com/user/major_major/media/F52A49C7-4616-4C96-AA9A-620D453096DA_zps37jm2l13.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/29B1EC1F-0E60-43A1-9BF4-58CF763FBC3B_zpsxnzlszst.jpg) (http://s736.photobucket.com/user/major_major/media/29B1EC1F-0E60-43A1-9BF4-58CF763FBC3B_zpsxnzlszst.jpg.html)

exciting times!! packed up the saber and went out to my dads shop to use some more serious stuff. (http://i736.photobucket.com/albums/xx2/major_major/9AD89D45-84BA-47F9-A2B7-CC6B10A96065_zpsusnvfipm.jpg) (http://s736.photobucket.com/user/major_major/media/9AD89D45-84BA-47F9-A2B7-CC6B10A96065_zpsusnvfipm.jpg.html)
The initial thought was to use the miter saw to make the cut- but looking at it we realized was gonna lose too much material making the cut that way, the area is just so tiny.  so instead we made a miter box on the band saw and then used that to simply hack saw it off with plenty of control.  Turned out great :). 
(http://i736.photobucket.com/albums/xx2/major_major/78B23319-BB00-424A-B407-F5F6AE7A2BFA_zps8n1m1ruq.jpg) (http://s736.photobucket.com/user/major_major/media/78B23319-BB00-424A-B407-F5F6AE7A2BFA_zps8n1m1ruq.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/48E82703-D58B-4D63-99A3-82C820FE9799_zpss4h5aihs.jpg) (http://s736.photobucket.com/user/major_major/media/48E82703-D58B-4D63-99A3-82C820FE9799_zpss4h5aihs.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/0A8B17F5-635A-4ABD-9767-C94A827EE1C7_zpsb5mwoxtc.jpg) (http://s736.photobucket.com/user/major_major/media/0A8B17F5-635A-4ABD-9767-C94A827EE1C7_zpsb5mwoxtc.jpg.html)
There's just something so appealing about looking at saber parts/ pieces all broken down/ laid out isn't there?  Prob doesn't look like it, but it's crazy how much time and work went into getting this handful of parts to where they are now lol!  But gonna be SO worth it- really pumped, now things can really start to come together :).
(http://i736.photobucket.com/albums/xx2/major_major/6EB1C888-44D4-4EA4-B53A-44E7A76F0579_zps139rzcb2.jpg) (http://s736.photobucket.com/user/major_major/media/6EB1C888-44D4-4EA4-B53A-44E7A76F0579_zps139rzcb2.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/F3DF8201-650A-42E9-B8E9-458FA06CAD74_zpswsdfsnkv.jpg) (http://s736.photobucket.com/user/major_major/media/F3DF8201-650A-42E9-B8E9-458FA06CAD74_zpswsdfsnkv.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/89D8D482-E5B3-4356-A329-4A944D15BFF9_zpsjrq8mnrk.jpg) (http://s736.photobucket.com/user/major_major/media/89D8D482-E5B3-4356-A329-4A944D15BFF9_zpsjrq8mnrk.jpg.html)(http://i736.photobucket.com/albums/xx2/major_major/C5E7DF2C-639A-4481-820B-E666C1A75181_zpsc8kkb1ni.jpg) (http://s736.photobucket.com/user/major_major/media/C5E7DF2C-639A-4481-820B-E666C1A75181_zpsc8kkb1ni.jpg.html)

hahahaha!!  that's Awesome :) thanks man!  I'm really loving that spring raffle custom you did- the proportions and just how all the little details and lines jive so well, it looks like it should be a saber in someone's regular line up.  Especially like the splash of gold and those grips :).   

Really coming together awesomely. Pretty soon it won't even be considered a US saber . Lol

Thanks Bulvoy and Calculon!  I always see these pics of other major players hilts all done up with like the crazy harp and yoda reveals and stuff like that, but you never see UltraSaber hilts with that kinda thing- and i know i have a long way to go before i can ever make something that even resembles that caliber of work, but eventually i wanna start crank'n out US with those amazing brass, almost steampunk style, reveal chassis etc :). 

painting some parts, also finishing up with the reveal, but been distracted this week... still being super productive, just went deep on a tutorial for recharge ports and a couple other things, but no worries, by tomorrow i'll be done all these mini side projects and back full time on the stunt.  Good to take a break every once and blue moon and keep things fresh :). (http://i736.photobucket.com/albums/xx2/major_major/99B87E22-F486-4219-8ACA-40B28CDF23BE_zpsbcbfva21.jpg) (http://s736.photobucket.com/user/major_major/media/99B87E22-F486-4219-8ACA-40B28CDF23BE_zpsbcbfva21.jpg.html)
(http://i736.photobucket.com/albums/xx2/major_major/2DA0667C-3B95-4607-96C7-06B0FF84A6E1_zps9txn1c6v.jpg) (http://s736.photobucket.com/user/major_major/media/2DA0667C-3B95-4607-96C7-06B0FF84A6E1_zps9txn1c6v.jpg.html)
the box is for my raffle entry project which will be done by tomorrow and posted :).  Wait till you see that, it's gonna be sweet!

You're not done are you?!

O no way not even close!  I've still got a ton left to do on this.   Still picking away at all the little things like crazy, will have more updates soon :).  I let myself wander into a quick little side project just to take a break/ keep things fresh.  Really happy with how it turned out, and worked like I was hoping- really excited/ re-energized to get back at it.  If you haven't seen you should check that side project out, was a lotta fun. 

Next order of business here is completing the upper portion of chassis, where the recharge port and kill key will go.  Then I need to start assembling and wiring this whole pommel/ reveal chassis/ switch piece- it all needs to be put together and wired in in a very specific order/ way.  But I'll be able to have this whole added piece finished and working with the leads sticking up ready to attach to rest of internals- then I'm just wiring it all together :).  Doesn't sound like much, but the way it all plays out is actually still a huge amount of work. 

Keep you posted.

An insanely meticulous amount of work you put into this  :o.  Looks great!  Have a -1 point on me.

Whaaaaaaaat..your last post was in July?  :D.  Howz bout an update.  Maybe some pics.  We need to see this through to completion.

Hahaha!!  Fair enough Zing lol ;).  I'm still picking away when I can- but I've literally got 6 projects on my bench ATM, and not one of them is mine lol!  So as soon as I finish up eveyone else's projects, it's go time again in big way :).  Keep you posted!  Will be SO worth the wait! 

Heheh, oops! sorry for taking you away from your own projects man! mine can wait, no worries!

O no worries Corwyn!!  That's just how it goes when you wanna do mods- mine can wait, they're not going anywhere.  Gotta take the opportunities as they come :).  Besides it's nice to pick something back up and have it feel totally fresh- especially something you go that deep on lol.  It can stagnate.