Saber Forum

So, I'm trying to find out what dimensions I should be looking at if I want to make a custom hilt myself.  It looks like most places use t6-6061 aluminum pipe or tube, around 1.5 in outer diameter (at least, that's what it seems like reading descriptions).  What would the recommended inner diameter and wall thickness be?  I was  looking at https://www.onlinemetals.com/merchant.cfm?id=71&step=2&top_cat=60 to order from, but I'm not sure which would be the best choice.  This is going to be for a set of shoto tonfas, ideally similar size to most MHS compatible stuff.

MHSV1 compatible parts have an inner diameter of 1.25".  You can, of course, go slightly smaller, but you're going to have a harder time fitting electronics inside something too much smaller.  This number isn't necessarily consistent throughout.  Ultra Sabers hilts that don't have removable emitters have enough space that's got an ID of 1.25 inches for the electronics, then the ID goes down to around an inch.  This allows features like deeper cut details, such as the deep choke points on the Aeons, Sentinel, Prophecy, etc.  All emitters, removable MHS or fixed, have an ID of 1 inch, or just a hair over, to fit the blade.

Anyway, I hope that helps. You can, of course, do whatever you want, but you probably want to plan out your electronics ahead of time, to ensure you don't run out of space.

http://www.saberforum.com/index.php?topic=4779.msg60014#msg60014


This might be helpful.

scifidude79 - thanks for the input on the ID and info on the innards and definitely a good tip about pre-measuring for the electronics. 

Jediseth - thanks for reminding me about that thread.  I'd been looking at the stats listed on various sites for saber hilt sizes and had forgotten about this particular thread. 

No problem.  One thing I love about US is how easy they make it to find specs on their hilts.  It makes things easier to plan.  :)