EASY KATANA SABER AND KUNAII BUILD PROJECT

[Ninja-Jedi]

he all wanted to start a thread to show how to make saber with no fabrication just a drill
so what I am making is a ninja katana style saber using sink tube and PVC and a PVC kunaii
so let get into it

First I started off with regular sink tube 1 1/4, 1 pvc cap threaded and 2 different PVC couplers .First I wrapped fine line tape(orange) around the body to form where i want my grip and spacing. to emitter section that is piece of phenolic board that i used a hole saw to fit over coupling, then i drilled hole for blue AV switch
here are some pics


 so now that i have the basic shape i want onto next step,  next i used double sided square tape and put in place for diamond section of saber then I took a peice of heat shrink and heated it up around the whole body and here is what I got



The last thing I will do to the body is a wrap with gray material not sure what I will use for that yet and still have alot more to do will post pics and show as I am making progress, I will be using 3.7V li-ion cell a heavy grade ultrasabers blade and guardian blue LED module more to come

[Moderator Nightwing]

That looks awesome!  I've always like the idea of a katana saber.  keep up the good work and be sure to keep us updated!

[DarthCooper88]

 Looks like you have a ton of room for an MR board & the batteries to run one, I do know of someone who has pre-wired complete MR circuit boards with battery packs & quick disconnects (it's not me LOL) Either way, neat saber!

[Ninja-Jedi]

yeah im still not sure on sound i could fit pretty much any soundboard in here hint hint darn you ultrasabers put the obsidian back in the store lol but on serious note this build i wanted to do for people who may not
have much in the way of tools at home and or experience so i want to keep it fairly simple.  Orginal plan was to make this a stunt without sound but i can always add sound later if i get bored with it.   One a side note as far as body design in the pictures the diamonds look a little round with heat shrink which isnt really a concern as they are just there for a reference when i do the wrap, and i left the bottom without diamonds because i want to incorporate like a metal dragon or something in the wrap which i have seen on actual katanas

[Temple]

Thanks a pretty cool idea

[Amanita]

The heatshrink is a great idea, where did you get it big enough to fit over a saber hilt?

[Ninja-Jedi]

got online u prob wont find at any hardware store in that size, i had it laying around from a past project but the grip can be done alot of different ways, I used the heatshrink to prevent less slipping when I do the wrap. Another cheap alternative would be baseball bat grip tape or something similar, then u could do wrap right over it. Also did a little more work this weekend will post some more pics tommorow.  I think the place i got the heatshrink was cableorganizer.com it was like $7 a foot for 1 1/2 diameter or something close

[Master Rel]

Shockingly cool.

It went quickly from "hey this is looking a bit of poo...those pieces will fall off" to "oohhhhh very nice, a dermal effect...clever clever"

 

[Veldryne]

props for the ingenious build mate, light side points for that one

now most of the people on the forums are gonna be casing everything in there homes wondering what they can turn into a lightsaber lol

[Ninja-Jedi]

cheated a little bit and got out dremel to round in the corners on emitter peice, I just wanted this look. It is
optional and if you dont have a dremel at home u could cut the corners with a saw and buy a round sanding drum for a drill, hand sanding would take forever, After that i just cut another peice of sinktube to go around pvc blade holder, and painted my peices with black enamel base coat, now i just need to wire everything up, i will use JST connectors for quick disconnects then I will epoxy everything together with some industrial strength epoxy and set screw everything in place and this will be done except for the wrap job, which I am new to doing wraps so prob be some trial and error there, also that is just an o-ring on top it will be PVC  but I am painting that peice seperately

[Veldryne]

it just keeps looking better and better

[Darth Nekesus]

it just keeps looking better and better

but does it work yet.

[Ninja-Jedi]

No the switch is just sitting in the hilt for picture, I havent wired anything yet, but this is just a GB LED, latching switch with LED and battery not even gonna use a buck puck cuz I dont need it for this, I do have 2 extra puck pucks but I am saving them for future builds with RED LED's it will only take about hour to wire up I just got to solder a couple wires with quick disconnects on LED and Battery

[Master Rel]

Dude...did a toy box throw upon your bed?  lol

I like what you did with the dremel...s'nice!

[Ninja-Jedi]

OK the Ninja saber is pretty much done. I just need to do the wrap on it. I am at work now but I will prob post a short vid tommorow, I kinda went of scope and added a qui gonn board cuz i had one laying around. I wont explaing the wiring on it is fairly simple, the only thing I did differntly i wire the negative from LED on switch to the negative for the speaker on the board. Now my LED switch fades with the sounds it still clashes with the blade as well. Basically the effect is that the switch is constantly pulsing to some degree which is what i wanted. When I wire up the Kunaii this weekend I will post pics of wire job since it will be real simple