The " Menace Project" A Grey Jedi's Saber

[Bulvoy]

Good Evening,
As some of you may know i just can't leave anything alone, I decked out my manticore a while back, This time I have my concept for the Menace. 2-channel Emerald B+S  FOC V4 sound.
 Extra parts, I ordered  a Raven SS pommel  & an extra  menace emitter in black since i will be providing various contrast on the entire Hilt.

I will be making the windows bigger, texture on the inner sleeve, slight paint job on lines, risers on the grip, My method of leather a wrap, a medallion.  project will be in a couple of phases.
                                                   Tools for this phase- Drill , Dremel  & Needle Files 
Phase I - windows in the emitter Bigger. As i quickly found out the aluminum is alot tougher than some would think. the outer sleeve, easy, the inner core MUCH thicker. i drilled pilot holes, took some meat off with my dremel,( careful not to mess up the existing shape & weaken anything) then switched to needle files to get the shape/angles i wanted. (LONG PROCESS, 7 man hrs LOL.)
This is just the outcome on the fit, Of course later on ill touch up the lines with paint.
PILOT HOLES

Dremel, Them Filing Begins on outer sleeve, I decided i wanted the top when looking at it different from the underside

Inner Sleeve work, again Dremel then  needle files, this part took a long time, because of the thickness.

As i worked i thought lets make some texture to show off the inner sleeve

After many test fits to line up the new exposed windows Im pretty satisfied with the outcome, the edges will be touched up with the paint job later.

 Thanks for checking it out. Lots more to come.....

[Drahcir]

As someone who is constantly putting holes in this aluminum I appreciate the man hours statement lol.

I'll be following this to see where it goes.

[JediXIX]

I'll be following too . . . a lot to like here Bulvoy . . . . +1 

[Daximum]

Also excited to see this

[hazard502]

You got after this one pretty quick Bulvoy ... lol   Looks good and requires that steady-even hand  ...  +1

[Hansrad]

Amazing start Bulvoy! Can't wait to see how this turns out.

[Landen Se-Sentien]

Duuuuude!

Point, and I'm posting so I can follow the progress on this thread.

[blackrockminerson]

I really like it. keep up the good work and keep us posted!

[RevanReborn]

SWEET!!  Epic start to what's obviously gonna be an epic mod!  Aweome work with the windows.  Eagerly watching this one .  Points. 

[Krell]

Cool mod on the windows. Love it

[sedstiskyfaller]

Definitely going to be following this one! Beautiful start to this project. Haven't seen much customization done to this hilt, so yours will be one of the first 

[Bulvoy]

Thanks everyone for the warm appreciation. I'm no professional by any means. Long ways to go. But fun. Going to do some emitter work and distress some leather today somewhere between  my daughters softball practice. ( Coach 4 yrs running) And the woman wanting to go out tonight lol

As someone who is constantly putting holes in this aluminum I appreciate the man hours statement lol.

This gave me even more respect for your projects. The dremel can be a little too wild at times for very small controlled lines  even with the  flex attatchment so yeah sore fingers with needle files was the way to go. It defiantly surprised me the toughness of inner sleeve.

[Shield madien]

Very Sweet !!!  Amazing like always. That's how the windows should come  . Can't wait to see your leather work +1

[Bulvoy]

Alrighty phase II.
 work done:
 Cut grooves in Emitter itself
Added Angled holes in Emitter for more light.
Scroll work in Aurebesh
start of the paint job.
     Its still ROUGH, need touch up on paint, and smooth out some lines on the engraving,  here i cut/ filed grooves on the Emitter itself, to match the grooves on the raven SS pommel, Added some Aurebesh. It spells out " Fortitude ". Been a long time i engraved something so, its a little sloppy. Gave it a quick paint job so i could see it better, will be going back for re- lines, and a surface polish. added some texture to the outer grooves.
 I added some more holes to pass some more light through. I drilled at an upward angle, so that the light when passes through goes downward, and it produced a unique reflection.


Finally painted the sleeve housing, i will be going over it with more black, cause at this point it makes me think tie-died shirt pattern, i may remove it all and go for a crackle pattern. thats it for now, next up leather risers and wrap

[RevanReborn]

Wow man, this just keeps getting more impressive!  LOVE the aurebesh on the emitter.  The windows are a nice addition too, they do throw the light down in cool way.  Engraving is such a pain lol, I'm STILL working away at mine- I need to give myself breaks by working on other aspects of my mod for periods of time just because i get sick of the etching!  I find that when I return to engraving again, even after such a short break, it feels like I'm totally rusty/ starting all over again lol- so can only imagine what a pain must have been if haven't done for a long time.   Point incoming.