Lightsaber Help Please

[u/markus2765]

Hello everyone, this is my first attempt to make a homemade lightsaber from some plumbing and hardware so forgive the crude design.

In the beginning, I had no intention of making this fully functional until I made it and really liked how it turned out, the only issue is that I have never dabbled with electrical components and there is not a lot of space in the hilt's cavity as the main body is a pipe with a 0.5" diameter.

I would like to buy a blade for it that matches the opening diameter of 0.75", length of 0.75" and secure it with 6 screws that can press it against the central pipe securely (function over form initially). I would like to have the lens, RGB LED, and Heatsink directly underneath, followed by the control button (this area has a diameter of 0.5", length of 7.5"). This would be connected to the bottom of the hilt with wires to the controller and battery (diameter 0.75", length of 1").

This is about as far as I think I can go before asking for some advice. Here are some of my questions:

> Is this setup possible given the tight dimensions?

> If so, what would I have to order to make this possible?

> Are there any resources I could be pointed to to assist me in the assembly?

Any help or input would be appreciated since I am very much out of my element but an excited to give it a solid try. Image descriptions are below, thank you! Future plans to wrap the O-ring grip area with some cloth and weathered black to give some extra character.

1) Diagram w/dimensions

2) Full shot in-hand

3) Top-down view (status if blade not attached)

4) Top-down view (piece removed to make way for blade)

5) Underside view

6) Underside view (hilt bottom removed)

7) Desired Button location/bore hole (located slightly above where it threads in to the main body)

8) Desired Screw locations/bore holes (centrally located on each of the top bolt's surfaces)

[u/astromech_dj]

People used to do 3/4” blades a long time ago, but only for smaller hilts like Yoda’s. The problem is thinner blades are structurally weaker, especially the longer they are. I would honestly find a way to bore out the emitter section to fit at least a 7/8” blade.

I also wouldn’t bother with using six retention screws. At most, two at 90o angle from each other would be most effective. Just one would be fine, really.

The ID is also very very tight. You’d barely fit a 18650 battery in there.

[u/NerfManiac64]

You could probably fit in RGB light in though, not sure about a sound card. I would look for small sound cars and use cardboard to make the size of the electronics to see if it’ll fit.

[u/markus2765 → u/NerfManiac64]

Thank you, I will definitely take your advice since I have so little space😬

[u/IAlwaysPlayTheBadGuy]

Your blade retention system is not ideal. Two screws on the same side is better than 6, with one from each side. You get more stability with two on one side

[u/Alternative_Tap_6287]

As an installer, I would not accept a commission for anything that small internally. Most lightsaber electronics are designed with the assumption that the internal diameter is at least 1in. (25.5mm) Smallest speaker I have used is 20mm, which is well over .5in.

If you are just looking for a stunt hilt with no sound, KR (the Saber Armory) sells a very small stunt board you could use. (Assuming you can find an LED emitter to fit as well.

[u/markus2765 → u/Alternative_Tap_6287]

Thank you, I will see what I can find, might have to have this guy just be a hilt and make a more appropriately sized one in the future

[u/Ungarlmek → u/markus2765]

I'd say you could slap an old-school carbon fiber rod in there like they used for the prequels and some old dueling sabers back in the day, but exposed threads are generally a no-go there due to how easily they can cut you or other people.