Savi's Workshop / Galaxy's Edge Lightsaber Blade Insert

thingiverse

This end-cap is designed to fit the chassis sold at Galaxy's Edge / Black Spire Outpost / Savi's Workshop as a finishing touch for your Lightsaber Blade. I've tested it out and it fits perfectly. The saber seems to like a 1.10" diameter insert, with a 3.20" depth - the last 0.20" of which is a rectangular plug and pogo pins. The inner diameter of the sheath is 1" to fit a 1" polycarbonate tubing blade. Inside the sheath, you can put one of two different files: a basic round insert or a 3.1" high shuttle that will occupy the full height of the sheath. Both inserts have space for three nails or tacks to be inserted as conductive pads that the pogo pins inside the saber will contact against. You may need to machine the holes a touch larger with a drill bit depending on what nails you have, but remember to hit them with sandpaper first to remove any non-conductive coating and file down one edge if it overhangs the rectangular hole in the middle. The shuttle insert has cutouts on the sides so that you can access the platform in the middle - an Arduino Nano should fit easily on it, and power itself from the GND and VCC pins. The cutouts will also give you access to solder your wires onto the nails or tacks used as contact points! For more information on the three pogo pins that the saber chassis has, identifying GND VCC and Signal, and the like - the Dead Bothans Society @ Burbank Makerspace has a great primer here: https://www.deadbothans.com/videos/ ("Galaxy's Edge Custom Blade Build Part 1: Reading Data from the Hilt"). Plans for future revisions include changing the external bumps to be metal for durability. Possibly using fasteners like https://www.boltdepot.com/Product-Details.aspx?product=14315 joined with https://www.boltdepot.com/Product-Details.aspx?product=6912, with the heads turned down or filed down to the proper diameter (0.2" for the machine screw and 0.3" for the less common screw bolt thing).