This is what I managed to get done yesterday before going off to work at the real job. ;D
I started off by cutting the chrome tube down to size...I went with 5"on this piece. That should be enough to house everything that will go into this section, the pommel mount, speaker, battery and probably the RICE port on a pigtail since this one's battery pack will be removable:
The un-threaded section of the MHS parts goes in one end:
It has a nice flush fit with the end of the tube...I squared off the tube and the MHS piece on my disc sander...sorry no pics of that. :-\ This piece will be held to the chrome tube using a few 8-32 button head screws. The forward grip piece will fit inside this part and will have a nearly press-fit secured further by the aforementioned 8-32 button head screws.
The pommel mount fits in the other end of the chrome tube, obviously:
This also has a nice, flush fit. This piece will also be secured to the chrome tube via 8-32 button heads screws, and also the CT button screw. I'll add those later, after I finish up the forward grip section.
Here's the rear grip section as it is right now:
This part will likely get my tubing cutter grip marks in a pattern I have yet to determine...
For the forward grip section, I'll need to cut down the 1.25 x 1.15 aluminum tube. I'll use the tubing cutter for that, since it isn't that thick, and being as short as it is, would be nearly impossible to do on the mitre saw (no way to really secure it due to the design of the saw's table):
The tube will fit into the two MHS pieces seen here:
This is basically how I make the Padawan Series sabers I also build, and they seem to hold up to some spirited dueling, so I know this one will be pretty sturdy as well.
These grip tube will slip into the MHS parts like this:
The intent is to have to practically press-fit the parts, to maintain structural rigidity, and alignment so we don't end up with a bent saber. (I've done that before on a couple of others in the past for myself....oops.)
I'll have to hone the inside of the MHS parts for this work, since the I.D's of the pieces is identical to the tubing's O.D. of 1.25".
This is my 1.25" cylinder hone I got from McMaster-Carr.com. I attached it to my variable speed drill motor, and this won't take long, due to the low amount material I need to remove.
I fit the hone into the MHS part:
I started with the emitter mount and because I didn't want to hone the threads, too, attached the emitter to act as a stop for the hone.
I put on my heavy-duty leather glove:
Another option would be to put the part in a vise, but I was not going to run the drill very fast, so friction heat build up isn't a concern this time around.
After a few minutes of checking and honing, the parts fit:
I did the same to un-threaded piece, and eventually it fit as well:
cool...it's starting to look like a saber!
I happen to have a piece of chrome tubing I cut for something else and hadn't ended up using, but it seems a perfect fit for the cover on the blade mount:
Now the real work begins....next post!