I have a suggestion: Dont get crazy trying to fabricate unecessary things for your saber, i.e. saber sleds/chassis. A lot of people start off with MR/Hasbro FX boards cause they're plentiful, inexpensive and sound pretty good. If you're making an MHS based saber, the little cradle that most of the sound boards come in, when you take off the top half, will slide nicely right in the MHS hilts, BAM! No need to make crazy PVC sleds or some elaborate chassis, especially if you're new at this. I can post pics if necessary DT. ;D
Also, a Dremel Fu Kata: As much as possible, when using the cut off wheel on your Dremel to cut sink tube, go AGAINST the rotation of the wheel. This will give you more control and not let the wheel control you resulting in gouges and run offs. It will also cut faster.