QUI-GON-JINN's (Jay-gon Jinn's) BS-2 Crystal Focus 2.63 Install

[QUI-GON JINN]

Well,  I finally managed to get one of Erv's slices of buttered toast,  as it has been warmly referred to since it was first introduced,  and decided that the best place for it weas in BS-2,  my personal favorite out of all of the brass sabers I've done this past year.  This did have an Ultrasound v1.0 in it,  but the board developed some problems,  and will be returned to our very own DARTH TYRANUS for repairs later.  Then it'll go into something else!

I started by dismantling the saber:

I wanted this to be rechargeable,  as it needs to have a way to kill power to the board,  and the best way is with a kill key in a recharge port,  so I began by modifying a 4-AA battery holder from TCSS.  The only probalem with this is,  the CF requires mounting in the bottom of the hilt,  so the batteries need to go in the ribbed extension...only thing is,  that pack doesn't fit with the batteries installed.  Seeing as how TCSS was out of NiMH packs,  and I'm inpatient,  I decided to do what someone else at TCSS did,  (I forget who) and modify the battery holder:


I drilled a couple of holes to allow me to insert the tungsten cutter in my rotary tool so I can remove some of the center divider of the battery holder.

I put the holder in the vise on my drill press and let the plastic fly:

That was easy!  I cleaned it up a bit:

I put some batteries in it,  and checked the fit:

Cool!  I'll remember to do this again if need be.

I also had to make some kid of holder for the CF.  That's the white plastic tube seen in the first pic.  It is a piece of 1.25" pvc drain extension.  this is the type used to replace the plumbing tubes we usually use under your sink,  not the heavy sch. 30 or 40 stuff found at the hardware stores.  I couldn't do much with it until the board arrived,  except "whittle" it down to fit inside the tube.  (No pics,  sorry...wasn't thinking!)  It slid in and out of the MHS extension just fine.  I also drilled the holes for the switch wires to pass through.

[QUI-GON JINN]

Okay,  the board arrived and I did a bit of test fitting:


You can see the cradle there in that shot.  I had also begun to wire the board,  by attaching the led leads and the speaker.  The CF will sit inside the cradle like so:


After testing the assembly by adding the ribbed extension,  and then the battery pack, I determined that the batery pack was too long to fit.  Bummer!  Well,  I guess I'll have to skip out on a recharge port and kill key,  and just go simple with it:

I'll use a set of Li-Ions instead.  I'll just take the battery pack out when the saber's not in use.  It might seem like a pain in the behind,  but really,  it's not that hard to just to remove the emiiter,  the led,   and unplug the battery pack.  I had to modify that battery holder,  too,  so the batteries would fit in the ribbed extension.  they'll connect to the CF with a 9-volt style snap connector.

Next up was to figure out the placement of the switches.  I thought it best to just put them both in the circuit board in the clamp's box:

I think that'll work!


Yup,  it sure will!

[pickupman63080]

I'm liking this already

[QUI-GON JINN]

I've got lots more to post,  hang on!

[QUI-GON JINN]

With the battery solution done,  I began to solder up the board:


I added the positive switch wires and the battery leads,  leaving a splice for the switch negatives:


I slid the board into the cradle to double check the fit:


I soldered the negative wires to the switches:

I also did the positives to test it out:

And it worked:

[QUI-GON JINN]

Before I put it together,  I adjusted the sound volume on the board,  using the pot that erv puts on them,  and thought,  I might want to change that later,  and the side of the board that it's on will facing the wrong way....so to take care of that,  I drilled and then enlarged a hole in the bottom of the cradle for it:


With that done,  I glued the speaker in place, using hot glue,  so if I ever need to replace it,  it'll be removeable:


A couple tacks of glue on the board:


And it was ready to go into the double threaded female extension:

[QUI-GON JINN]

I slid the extension into the brass tube:


I added the CT knob to secure the pieces together:


Next,  I slid the clamp into place and installed the forward screw:


And pulled the switch wires through:


I soldered the switch wires:


I slid circuit board into place,  and installed the second screw.  The CB sits on top of the screws,  and is sort of pressure fit between the tops of the screws and the top of the box:

[QUI-GON JINN]

Next piece to go on is the ribbed extension,  where the batteries will be housed:


The battery connector fits right through:


And the batteries fit right in:


The next couple steps were easy,  of course...adding the led,  lens and the blade holder....so how did it turn out?

I'll let you be the judge:

[JANGO FETT]

Those Ultrafires will work with a recharge port and the Tenergy Li-ion charger from TCSS.

I just upgraded my CF 2.63 MHS LUKE V2 to a Lux V green and 2 14500 ultrafires last night. Coincidence? 

[QUI-GON JINN]

BEAUTY SHOTS:

[QUI-GON JINN]

Those Ultrafires will work with a recharge port and the Tenergy Li-ion charger from TCSS.

I just upgraded my CF 2.63 MHS LUKE V2 to a Lux V green and 2 14500 ultrafires last night. Coincidence?  

I really couldn't find a good spot for a recharge port,  so the removable battery pack will have to do for now!  It might also come in handy if I'm out to a Rebel Legion/501st costume event like i have tomorrow,  if the batts die on me,  I can just change them lout and pop in a freshly charged set.  I also couldn't wait to get it installed and just went the easy route!  ;)

[JANGO FETT]

I see ;)
Here's an idea for you. Putt it in the pommel!  ;D

http://www.thecustomsabershop.com/MPS-Insert-style-6-P263.aspx currently out of stock :(
you get the idea, though

[QUI-GON JINN]

You have a way of getting the wires around the speaker,  don't you?  ;)  I'll keep that in mind!

[darth_call]

This is great, not just the saber, .......I mean the saber is awesome, ...but you knew that already. The ideas, ingenuity and process you have showed in this pictorial will help a lot f us out were had the "how can we do this" questions.

Thanks Master Jinn, the whole setup is awesome!

[pickupman63080]

Thats DEFINITELY a saber to be admired, let me know if ya ever sell that bad boy