After weeks of planning I finally started on my 1:1 replica Orgus Din lightsaber.
It is still early but here are some photos of the machining process.
Emitter Collar
Emitter Front
Front with collar. The collar is a friction fit over the emitter front. It will likely be secured in place by a screw hidden under the shroud and / or superglue.
Stay tuned as I will continue to update this thread with my progress.
Completed work on the Pommel today.
Milled the axial and endcap slots using my rotary table.
Marked off the slot ranges with a Sharpie to make sure I did not over cut the slots.
Slots Complete!
2/28/2016 Update
More progress on the Orgus Din build...
Handle slots milled. The work pulled up slightly milling the reveal slot and almost ruined the part. I will be able to correct that with some filler as the wood will cover it up.
Grill and bottom bezel. The bottom bezel will be etched with a decorative pattern.
This is the auxiliary button bezel and plunger assembly. This will also serve as one of the mounting screws for securing the handle to the front.
More progress to come...
-Denzil