Well, I guess I can just post the pictures here, too.
This is what I started with in May of 2021...yeah, it's been awhile!
MPS pommel style 12 and a 28mm 2W bass speaker (that I didn't actually end up using on this one) and MPS insert style 1 with the c-clip.
MHS 5" double female extension and ribbed extension style 2. Also a 16mm flat AV switch bezel, that also didn't get used.
Battery is an 18650 3400mAh rechargeable protected cell, MHS blade holder style 27, a 16mm short AV switch (that I also ended up not using on this one, it went on BS-30) and a Copper Nova Cree XPE2 that I don't know what happened to....I must have used it on something else, too.
Basic assembly of the parts.
Cut the brass sleeve to length. You can see BS-2 in the background disassembled...I think that's where the copper nova led went...I upgraded that one to a CFX at that time.
Cut and made the brass collar for the ribbed extension.
I added some decorative rings with a tubing cutter, as usual. This piece was also epoxied into place.
The basic assembly, with the brass pieces!
Nice look a the new extension's smaller diameter grip area. this was how it sat on my workbench for awhile before getting boxed up and put into storage as my wife and I had tried to sell our house and move to a place outside of town with more property. That fell through and we are still where we've been for over 20 years. I recently unpacked all of this stuff and got my work space back into order and had some time to do this stuff again.
Fast forward to October 2023 and I drilled and tapped the saber for the switch, which is now a 12mm green ring and for the Covertec button:
I like the 12mm switches a bit better than the 16mm. Less bulky.
The Covertec button is in the usual place.
This one will get a battery chassis:
i'll be using a chassis recharge port mount instead of making my own c-clip.
The trick will be lining up the hole in the hilt.
I'll use the switchcraft 2.1mm recharge port.
Battery chassis discs...i'll use the broken set from BS-27 on this one, since they'll still work. This will only hold the battery anyway.
Installed recharge port.
Test fitting the chassis.
The battery barely fits.
Not much room for the wires, either so the speaker mount I had ordered for this one will not work.
TCSS does have a reversed mount for 28mm speakers that would essentially fit like this, putting the speaker in the pommel.
The other end looks like it'll work just fine for what I had in mind.
Time to work on the rear brass sleeve. Using the tubing cutter just snug on the tube will leave faux grip rings.
Done!
Not perfect, as usual.
I also added a couple in front of the switch hole to tie it into the brass collar on the ribbed extension.