EDIT 8-24-09---I finally finished my Leia. I got a US 2.1 and put it in. I had some set backs so I let it sit for a few weeks but finally decided I needed to finish it so I worked on it a little yesterday and got it done.
My updates on it are as follows.
1. US 2.1 added
2. 4 Li-Ion batteries in a series/parallel circuit (with 7.4V PC) for longer run time
3. accent LEDs...one for power indicator and the other for blade activation.
4. redid the pommel to use a recharge port (got the idea from Jango Fett)
5. added a tactile switch that is pretty much flush (but radius the hole to allow for easy pushing) and is in the perfect location for my pinky to activate the saber.
I still need to make a nice kill key for it that matches the rest of the hilt. That is just an old one I made a while back that really doesn't fit very well.
new pics and vid is added on post 25
I decided to do a little powder coating and polishing on my Leia saber. I already put a Luke ANH sound card and cre xre blue (was a p4 green but changed it...will probably change it to a Lux III cyan I forgot I had). I still have to put a kill switch in but I have just been pulling the sled and undoing the battery for now.
Originally I was going to just media blast the grooves and polish the rest but decided I needed to try out my super wet black powder. I polished everything and taped off the grooves (man that was a pain) and powder coated it.
I am still unsure how I like it but I think I will leave it like this for a little while whither correct by the book or not.
On with the pics.
click for larger pics...