Custom Lightsaber #2 - No Supports

thingiverse

This is a custom lightsaber handle that I designed for a friend. It measures about 13" long. I took design cues from the classic Skywalker lightsaber but added my own twist to it. I tried to make it look like an actual electro-mechanical device with the heat sinks/vents, circuitry on the upper handle, and fan blades at the emitter end. For assembly, you'll need the following: * a couple small tubes of super glue * the double button variant of this thing [here](https://www.thingiverse.com/thing:4664759) * the belt clip assembly from this thing [here](https://www.thingiverse.com/thing:4547048) Print out one of each part except for the following: * 6 emitter_bolt * 2 heat_sink_backing * 2 heat_sink * 2 heat_sink_screen * 3 handle_washer_1 * 2 handle_washer_2 * 7 handle_grip_strip * 6 handle_lower_slat **Note:** on the **handle_ring** piece, there is no symbol on that piece. The printed piece in the pictures was a one-off custom piece for a friend and isn't in the final STL. **Assembly** **Upper handle** Glue the **emitter_heat_sink** into the end of the **emitter_shroud** and glue the 6 **emitter_bolt**s into the holes around **emitter_shroud**. Glue the shroud onto the top end of **handle_upper** (the oval hole for the button is toward the top). The tall part of the shroud should be in line with the oval button hole. Glue a double button assembly (link in description above) into the oval hole. **emitter_collar** will go around the button and the wide end will butt up against the bottom of the emitter. In the rectangular holes on the side of **handle_upper**, insert **heat_sink_backing** first (bumps/slots outward), then **heat_sink**, then **heat_sink_screen** last. **Lower handle** There are 8 wide slots on **handle_lower** but one is shorter than the other 7. Glue the 7 **handle_grip_strip**s into the long slots on **handle_lower**. Glue the shorter **handle_grip_strip_short** onto the remaining short slot. The 6 **handle_lower_slat**s will go in the slots in between. Glue the **pommel** with the pointy protrusions pointing toward the bulk of the handle and rotated so the protrusions are centered in between the grip strips. The pieces for the pommel heat sink will be inserted into the open end of the pommel in this order: **pommel_heat_sink_backing**, **pommel_heat_sink**, **pommel_heat_sink_screen** (with the round side facing outward). The screen piece doesn't really snap into place, so you'll just have to hold it firm and square as the glue sets. **Final assembly** Slide **handle_ring** onto the bottom of **handle_upper** with the tall side upward. The tall side of the ring should be in line with the buttons and the tall part of the emitter. Slide the rings onto the top end of **handle_lower** alternating between **handle_washer_1** and **handle_washer_2**. Then slide the upper assembly onto the lower. There's a protrusion on the lower which should face to the left. This protrusion is where the belt clip knob will go.