Well I have been contemplating selling this saber but it wasn't quite up to par with what I would want it to be if I did indeed sell it (had a buyer and was going to make some changes if the deal went through). There were a couple of things that bugged me about the saber and I fixed them today. First was that it just didn't sound that good and wasn't very loud. I did the CF volume hack on it and it was louder but still not as loud as I would like. Another thing that bugged me is the switches I used. I just used regular tactile switches that I cut down so it just had the regular plastic plungers that were on it. Lastly the holes were not quite in line with the center and were off just a fraction.
The sound issue was because I just didn't have room to enclose the speaker so it was basically just open air all around it. I used of all things the top of a water bottle and it worked great and the saber is plenty loud and clear now.
I fixed the switches by replacing them with the lighted switches Jango used on the stormtrooper run (and others have used as well). I used a rivet as a plunger and a 3mm LED in the center for a lens. To do this I had to move the power extender to the top of the board. Only problem was that the cross bar would hit it if I did (barely but still would hit). I decided to take a razor and cut the wafer the power extender was on which made it much thinner. Problem #2 solved.
Lastly the problem with the switch holes being slight off was fixed because the plungers I used were larger than the existing plungers. I used my mill this time and was able to get them perfectly aligned with the center of the cross bar.
All in all I am very happy with the way it turned out and now I just have to decide if I want to sell it or not.
I am doing some beta testing for erv on the firmware I used (still in beta form) and I really like the pulsing ("breathing") mode for the accent LED.
Here are some pics of the internals (click for larger images)
here is the videohttp://www.youtube.com/watch?v=ycNQtW-se7o