lightsaber

thingiverse

Here's my lightsaber - it's a public file, and I ask that you don't sell it. You're more than welcome to use it for yourself. Now that's out of the way. Parts: 1. "Pex tube" from Menards (clearish white) Mine was a 5-foot straight stick cut to 40 inches ($6) 2. Flashlight from Menards ($20) or eBay ($8) 3. Flash gel on eBay, different options for $8 per pack of 20 colors 4. And of course, 3D print the two files I printed in one piece but you may have to break it down. The hilt prints upside down because there's a ledge inside. This way, you don't need support. http://www.thingiverse.com/thing:2024985 The pex tube will have black lettering on it just take paper towel and rub it off - it should come off with a little effort. Use small zip ties and a little superglue to keep the flashlight in an extended position (smallest focus point). Once the parts are printed, there's some post-processing to keep it strong. Tolerances are tight so clean up the plug and get it to fit inside of the hilt, then clean up the inside of the plug and get the flashlight bottom end to fit through it. Next is the hard part - you have to get the flashlight to tightly fit into the hilt. Get the inside smooth by using sandpaper on a dowel rod. The light won't fit from sanding, so you'll have to lightly grind the flashlight to get that perfect fit (reason being it's as tight as possible so it doesn't move around). Next, sand the inside of the hilt where the blade goes until it fits. Put the flashlight in the bottom and put the plug on. The flashlight will be tight in place. Now push the blade down to the flashlight so they touch. Then proceed to drilling holes in the next part. Drill holes to fit 5mm screws - one for the light (drilled through hilt and plug at same time without flashlight in) and two for the blade through the hilt and the blade. Install your two screws for the blade. Now take the light out and cover the end with a flash gel of choice, then reinsert it into the hilt. Put on the plug and put in your set screw - I used 10mm for this part. And there you go - a cheap lightsaber that looks awesome! I want to see them when you're done building them. And remember, may the force be with you!