Hi folks! I'm a new member (just joined today) but have enjoyed reading through the forums and soaking up all the information. Thanks to all who have shared their knowledge! Lots to learn.
I wanted to share some progress pics of my first saber build, which I started a few weeks ago.
The 'physical' build is going slow, which is actually nice since it gives me time to make decisions on electronics, etc. . .
The base of the saber is .65 wall 304 stainless pipe. Heavy! It's going to feel like a weapon. Here I'm turning some internal threads for the end cap:
Here's the threaded end cap, getting cut off on the lathe:
Here's the finished end cap:
The business end was cut/ground/drilled/filed using templates I stole off the internet:
Forming the 'bumps' for the eye and button was tricky.
I ended up making internal/external forms using pipe and a turned washer, and drawing them together with a 1/2" bolt.
The tooling took a few iterations to get right. Here's one of my test runs, using mild steel pipe:
The setup took a LOT of pressure, but worked well.
So I duplicated the process on the 'actual' piece, and threaded the holes for the repro eye and button:
Next step was to finish the 'bulb holder' mounting ears.
Top hole is 'plain' for a screw to slide through. Bottom hole is threaded:
That's it for now! Next challenge will be the bulb holder arms (bunny ears).
Oh, and lots more reading on electronics, blades, speakers, etc. . .
Happy Saturday, all!
-Jeremy