First blade is finished:
It uses 97 PL9823 LEDs, a packing foam sheet inner diffuser, than the TCSS 3/4" diffuser tube, and then the 7/8" diffused polycarbonate blade with a rounded tip.
Here is a brightness comparison:
The bottom one is a "Black Series Luke Skywalker Force FX Lightsaber", with reasonably new batteries.
The top is my new blade. The camera is exaggerating the effect a little, but my blade is a fair amount brighter, and that's with only the blue LEDs on. It should be roughly 3x brighter when white.