Thanks Goodman. You were a huge help in this build and I gotta admit, you pushed me to be able to do the trigger buttons. I'll be posting more build log pics when I do the second one (since I will be using all of the same braces and protectors) but I won't be doing a comprehensive tutorial. This saber would be best as a crystal shard conversion, as it would not only save about half of the work, but it would also allow the stock screws to be used to hold the saber together (effectively solving the mystery of sd card access).
For those keeping track, the curved section, elbow section, and grip section are cast aluminum, the pommel "wraparound" piece is machined aluminum, and the pommel, emitter, and grip ring spacer are machined brass. Also, the rubber grips are fine, they are just not currently attached. The 11 year old adhesive was ready to come off anyway, plus, it was necessary to remove them for machining the pieces. I should also note that I'm at least 20 hours into the build at this point (though the second one should be a lot faster due to already having the protectors and braces for each piece).
The saber will take a 3/4" blade, tri rebel (only a .65" light passthrough though to maintain strength of the machined coupler), 16340s, a CFv6, 20mm 3W speaker, 1.3mm charge port, and it will probably be sporting a brand new font some time down the road.