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The S.A.B.E.R. GUILD: Saber Manufacturers => Plecter Labs => Plecter Labs Portfolio/Gallery => Topic started by: erv on July 10, 2014, 01:36:56 AM

Title: Shadow Guard pike with CFv6
Post by: erv on July 10, 2014, 01:36:56 AM
I haven't posted any of my builds / installs for a while. That one is old too, but I thought I'd share as a customer recently asked about a pike install.
It was formally done with a CFv6 but I recently upgraded it with a CFv7.
______________________________________________________________________________________________________________________________

I met Jonatan at FACTS12, we started talking about having his pike equipped with electronics. I don't have much time along the year for my own installs but I though it would be nice to help a fellow RL / 501 member.

His pike is a nice item (can't recall from who he got that, RPF or else), good machining, all powder coated, and electronics ready. Comes in 3 or 4 pieces that screw all together.

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_00.jpg)

He wants a full power setup, no white FoC, basically the goal is a bright blade for posing with visitors during conventions, not much interaction or  duel or jedi-iscisms. Flicker though, will definitely add up and even if sound will always remain shy in a public space, he will enjoy that at home

There's not much room but fortunately, the designer has thought about a switch location and battery pack in the lower part, just below the emitter section. I initially thought about 18650 which were fitting but with no room for any wires and I'm definitely not equipped to bore a tube of 30cm long.

So I chose some non protected 16650, 2 cell pack, with 2 cell PCB added separately. LEDengin RRRR seriallel, no FoC, to have the max brightness all the time.
The first step was to machine a nice and sturdy chassis. As the tube ID is like 18 something, such a small wall to bore is always difficult in plastic (at least for noobs like me and without creating a custom collet for it) so I adapted a few bits of 3/4" blades for the ends of the batt pack. The blade segment connects then to a chassis milled in a PVC rod, with wire channels and shouldered section to welcome the switches and the protection circuit board of the batt. pack.

still very WIP, here are some pics

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_01.jpg)

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_02.jpg)

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_03.jpg)

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_04.jpg)

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_05.jpg)

Title: Re: Shadow Guard pike with CFv6
Post by: erv on July 10, 2014, 01:37:44 AM
Got the body drilled for the switches plungers. Stressing moment of proper clamping and centering, didn't chip off the PC job  8)

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_055.jpg)

Then final install of the chassis. Single hidden screw to secure it in place, it's already very snug inside, tight machining tolerance made so that polyC rings expanded juuust a bit to push a little once the cells are inserted.

Knurled Jango killkey = perfect job for this project

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_06.jpg)

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_07.jpg)
Title: Re: Shadow Guard pike with CFv6
Post by: erv on July 10, 2014, 01:40:04 AM
finished the install

Ledengin wiring.

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_08.jpg)

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_09.jpg)

Machined chassis, I milled extra room in the front to have the LED connector fitting.
(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_10.jpg)

(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_11.jpg)

tight fit with the front screw, used as a blade holder holder (it's like the green lantern lantern).
(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_12.jpg)

Result. I have to say that it's the first time I'm really impressed by a ledengin. Probably because my latest attempt had a 3/4 blade and limited current. 4 dice running at 1A = win. Newer leds probably beat that but 1.5 year ago, that was pretty bright !
(https://www.plecterlabs.com/Media/Divers/GuardPike/Pike_13.jpg)
Title: Re: Shadow Guard pike with CFv6
Post by: erv on July 10, 2014, 01:40:38 AM
customer returned to me, he's very happy and got his costume (and pike) approved by the 501.

gallery - blade wasn't photoshopped

http://plus.google.com/photos/106379627929213928636/albums/5867168248987360817?banner=pwa

(https://lh4.googleusercontent.com/-ER02Y6EbCV0/UWxevunxOhI/AAAAAAAAChM/64BQ_REegKM/s675/P1050030.JPG)

(https://lh6.googleusercontent.com/-LpUBL7ppTXY/UWxgAnzXKwI/AAAAAAAAChs/OF9KKDEex3w/s675/P1050035.JPG)
Title: Re: Shadow Guard pike with CFv6
Post by: Wildcard on July 10, 2014, 08:42:46 AM
That looks awesome Erv! And thank you for the great, detailed build log!
Title: Re: Shadow Guard pike with CFv6
Post by: Greebles on July 10, 2014, 09:45:02 AM
Nicely done.

I haven't seen very many of those done. Neat.

-Denzil
Title: Re: Shadow Guard pike with CFv6
Post by: erv on July 11, 2014, 04:32:19 AM
thanks guys. Nothing "complex" per say, just an unusual type of install and split of the electronics / batteries. Essentially custom machining, I totally enjoyed it.
Title: Re: Shadow Guard pike with CFv6
Post by: Wyrlock on July 11, 2014, 06:43:43 AM
Nice! I was thinking about building one as a project after playing TFU the other day...
Title: Re: Shadow Guard pike with CFv6
Post by: Professor Huyang on July 11, 2014, 06:46:28 AM
Sweet. I love a saber pike. Thanks for sharing erv.
Title: Re: Shadow Guard pike with CFv6
Post by: CHEWBACCA on July 11, 2014, 07:02:36 AM
That turned out great erv, nice thought out design and very neat and tidy!
Title: Re: Shadow Guard pike with CFv6
Post by: Justintmars on July 11, 2014, 07:57:10 AM
Amazing....

thanks for sharing.

Perfect item to top off a wicked cool costume!
Title: Re: Shadow Guard pike with CFv6
Post by: Cad-Bayne on July 11, 2014, 08:12:56 AM
Me likey!!!
Title: Re: Shadow Guard pike with CFv6
Post by: Iamhomostellaris on July 11, 2014, 08:56:37 AM
"Nothing complex"!!!!
Yeah CF7 is not complex at all  :))
Without joke this is a fresh and nice prop you achieved here, thanks for the share Erv!!