I would like to share a few tips on how to add sound to your PVC saber.
Tips to Adding Sound to Your PVC Saber Hilt
Here is a technique I used to add a Master Replicas sound board and speaker to a PVC saber - with this method, you can have an inexpensive hilt with great sound.
The key here is to use 2 different kinds of PVC:
1. Blade Holder : I use the gray electrical conduit PVC for the blade holder
since it has a tighter inside diameter to better hold the blade.
2. Saber Body : since the gray conduit PVC s too tight to hold the MR sound board and a 4 AAA battery pack - this is where I use the white plumbing PVC for the main body
Where does the speaker go? I house the speaker in the end cap.
For the speaker, I just cut it off the Master Replicas battery pack assembly with a dremel tool.
Here is a snapshot:
Make sure you use a screw to secure the end cap to your saber body and drill some sound holes.
I used a sink strainer as a stencil for the sound hole layout.Note:
this method works in the same way for an "economy" sound board/hasbro toy saber sound board.
I use 1" schedule 40 PVC tubing.
Here is a photo that shows the differences in the inner diameter:
Link to this pic: http://i662.photobucket.com/albums/uu348/Lonewind2009/Parts/PVCPipeCrossSectionSamples.jpg