Saber Saturday!

[Jev Moldara]

That looks really really good.  I'm skeptical as to whether wood would be strong enough for a hilt though.  Obviously this is Star Wars, so they can do anything they want.

It depends on the type of wood. Obviously normal pine would not suffice. I would recommend any wood with a Janka Hardness Test rating of 1000 pounds-force or more (putting you into the teak range and above). Really, the higher you go, the better, but harder woods require harder tools to cut them. Additionally, unlike softer woods, which can bend and flex, hardwoods are more difficult to bore out, but the end result is absolutely fantastic.

[Master Rel]

I have been tasked to make said wooden saber for a Christmas gift...so we shall see 

[Jev Moldara]

I have been tasked to make said wooden saber for a Christmas gift...so we shall see 

Go slow with boring the wood...

[Master Rel]

Go slow with boring the wood...

Thanks for the thought 

Wood milling was my first apprenticeship...restoration of antique furniture...mostly caning repair, replacing turned pieces, and matching stains.

I have a plan and if I can get what I am looking for then it will be no problem 

If not I will make it out of mesquite and then stabilize it afterwards.

[ThreadJack]

That wooden saber is awesome. Do want.

[Thonolan]

if you have access to a 7 axis CNC router (some fabrication shops have them) you can make almost anything out of wood.

Also, most of them take a .stl 3d model file to create the piece.

you could do i with a 1 piece hilt, a fitted (possibly even slotted) pommel. you could hold it in place with a round topped fine bolt, and a wing nut on the other side. use that to mount your d-ring.

It will be interesting to see. Good luck to you sir.

[Master Rel]

if you have access to a 7 axis CNC router (some fabrication shops have them) you can make almost anything out of wood.

Also, most of them take a .stl 3d model file to create the piece.

you could do i with a 1 piece hilt, a fitted (possibly even slotted) pommel. you could hold it in place with a round topped fine bolt, and a wing nut on the other side. use that to mount your d-ring.

It will be interesting to see. Good luck to you sir.

Yes all of that would be fantastic.

But I do not have access to that so I will have to rely on my 2:10 digital tool set to make it happen 

Currently I have two plans, the one is preferred but my current wood stock is too thin so it will depend on what I find this weekend.

Either way the best way to prevent stress shocks is to sleeve the inner section with a metal tube...which is my plan 

[Jev Moldara]

So... what? 1.375" OD (1.125" ID) 6061 aluminum tube with a .0625" thick outer wooden shell? That would yield the standard 1.5" OD hilt while still giving you room to put electronics inside (given that most sound cards are 2"x1")...

[Master Rel]

 

The support is for the saber itself.

There are issues to be sure...at this point I am going for look and saber with light source...again it depends on what I can get my hands on.

[Jev Moldara]

Why do I get the mental image of you touching your nose, Rel?

Oh, and for an intriguing thought, you can leave one end at 1.5" OD and just slide the shell up and butt it up against it, ensuring that you have a solid metal surface for the emitter to attach.