Continued from OP (Ran out of characters!)
Stage 6 - Install Part 1
So, from stage 5, I had already started wiring the bottom half of the saber. Everything has worked well and I fired up the NBv2.0. The battery was a bit low, so I wasn't happy with the loudness of the saber and for some reason after putting it on charge to test with a full battery, the sound was completely gone!!!! So now I think I may have a blown speaker and have to take the bottom half apart again and put a new mini speaker in. These things are so delicate, so what I will do is dremel a small slit along the top of the speaker holder/recharge port 3D part and give the speaker a breather a bit.
I did however machine my heatsink module and install it into the saber along with the switch.
The switch wasn't working great at first and I think it's because I had it resting on the heatsink rather than the top part of the gold button hole and I had it sandwiched between 2 strong VHB adhesive tape (the kind Yoda uses on his DIY chassis kit) and it just didn't work well. The switch setup is the hardest thing about this build and I need to get it perfect! so I will change that in the next few day and improve the switch setup.
But in summary, today wasn't the best of all of my install days and was a PIMA, but I am super tired and my medication has made me kinda drowsy so I'm packing it in and going to attack this again with a fresh start tomorrow or at the weekend....I gotta get this done!!!
Pics of some install below:
LED wiring:
Module:
Installed phase 1: