Ultrasabers Obsidian Lite Chassis with Mute Switch

thingiverse

UPDATE: Extra part added to the chassis now works perfectly in the Fallen! Cheers! The total length of this modified chassis is approximately 118mm minus the speaker handle. You can disregard this measurement if desired, as it's not necessary and doesn't attach nicely onto the chassis. However, its presence makes the chassis easier to pull out. Simply glue it on the bottom. Assembly proceeds in a specific order: battery, middle, and board section must be connected in that sequence. Be sure to measure carefully to ensure clearance for your lightsaber (from the bottom of the button to the top of the threads for the pommel insert on the hilt). My ultrasabers Fallen had an extremely tight fit; if you want it to work with a Fallen, let me know and I'll create a custom design that wraps around the chassis. The Fallen's button hits against the chassis top. Rewiring is required, along with removing the old speaker holder. To do so, cut the wires (disconnected from the batteries) and remove the bottom holder from the battery case. Then, use something to poke at the hole behind the speaker; it should pop out easily. Note that this part is not screwed in or secured by anything; those visible screws are merely for alignment. The battery case will need to be reused, but you can discard the old speaker holder as desired. For the mute switch, use a mini slide switch - I recommend this one: http://www.vimex.com/switches/pages/SWX-SLD-TKS-SS12D00-index.htm Connect (solder) the switch from any far end pin to one of the wires for the speaker, then connect the middle pin to the board. The second wire will go towards the board. If you need further assistance with wiring or accidentally pull something out, refer to the Ultrasabers Obsidian Lite soundboard schematic I've provided. Benefits of this chassis: - More solid and protected - Reduced shaking and less speaker screaming "OBSIDIAAAN" when dropped (can't prevent that, but it happens for some reason) - Less force required to initiate clash sounds from the saber - More consistent swing sounds - Looks amazing Drawbacks: - Installation can be a challenge, especially in low-clearance hilts like the Fallen - Can be difficult to install in tight spaces