Greetings fellow Jedi (and those who lean to the dark side, too,
I guess 
).
Here are a few pictures of the Standard Issue Battle Saber that I received last week. The color is Guardian Blue:

This saber is a 'two piece' design. It has a single hilt/emitter, and a pommel. This unit is the VERY basic battery, Resistor, Switch and LED Module.

Being an engineer type of person, I did what any engineer would do. I got out my calipers and started measuring!
You know how they say the the emitter opening is meant for a 1 inch blade? Look just how accurate the 1 inch bore really is:

1.0005 inches. That is beyond the level of accuracy really needed here frankly! Also notice the thickness of the aluminum here - this is the thickness of the hilt all the way through, except where it had to be bored out to make room for the batteries.
Next, a shot of the solid pommel:

It is .87 inches thick of solid aluminum.
Now a look at the bored out area of the hilt, done to make room for batteries (and room for the optional sound board, too):


It has been bored nearly 4 inches deep. If you subtract the threaded area where the pommel screws in, the real available area is about 3.3 inches of bore.

That shiny circle 'down the hole' (that the camera didn't want to focus on) is where the larger bore ends and the hilt walls are full thickness again.
For those that have not seen a blade plug in an angled emitter - well now you have:

OK - That is my simple review on the excellent build quality and immense strength of the saber's hilt.
One more required 'Hero' shot of the saber:

And we are done! Happy Sabering everybody!