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Author Topic: Jeremy.G's scratch-built Skywalker  (Read 16502 times)

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Offline jeremy.g

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Jeremy.G's scratch-built Skywalker
« on: August 26, 2017, 07:39:21 AM »
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







« Last Edit: September 25, 2017, 07:58:21 PM by jeremy.g »

Offline TheSaberCore

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Re: Jeremy.G's scratch-built Skywalker
« Reply #1 on: August 26, 2017, 07:44:01 AM »
Wow, can't help but admire home-built Graflexes, truly impressive. Good luck with the rest of your build!
"Luke."

"The Belonging you seek is not behind you, it is ahead."


Offline Thexter

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Re: Jeremy.G's scratch-built Skywalker
« Reply #2 on: August 26, 2017, 07:47:24 AM »
Very cool! I like how you made the bump.

Offline jeremy.g

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Re: Jeremy.G's scratch-built Skywalker
« Reply #3 on: August 26, 2017, 03:35:07 PM »
Thanks guys!

I made some progress on the bunny ears today.  This part is daunting; I was tempted to just buy some repro ears and be done with it.  But I'm happy with how they are coming out.

I started with a cardstock template of what I *thought* they should look like:



I cut two of them out of steel, then stacked them so I could file them to match.



Like so:



The 'ears' were then bent around a mandrel with vise and hammer, and drilled.
Installed, they are starting to look the part:



Now on to form the interior parts, to fit a 1" blade.  I think I'll make the blade holder first. . .

« Last Edit: September 25, 2017, 08:01:09 PM by jeremy.g »

Offline jeremy.g

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Re: Jeremy.G's scratch-built Skywalker
« Reply #4 on: August 28, 2017, 08:12:44 AM »
I started fitting a blade holder, cut from aluminum.
I still need to bore it out to 1" for the blade, and figure out how I want to cut/file/drill to fit buttons, wires, etc.

Definitely making this up as I go along. :)





« Last Edit: September 25, 2017, 08:02:04 PM by jeremy.g »

Offline Greebles

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Re: Jeremy.G's scratch-built Skywalker
« Reply #5 on: August 28, 2017, 08:25:47 AM »
Very impressive! Not many people have attempted this AFAIK.

-Denzil

Offline jeremy.g

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Re: Jeremy.G's scratch-built Skywalker
« Reply #6 on: August 28, 2017, 02:30:08 PM »
Thanks Denzil!  It's definitely a lot of effort, and not a project for someone in a hurry. ;)

I've been reading up on board and blade choices.  And watching lots of Space Windu's blade vids.

I think I want to do a neopixel/strip blade, or build a similar 'string' blade.
For board, I think I talked myself into a Crystal Focus, if the next version will do Neopixel LED's.

Anybody got insider information on when the next Crystal Focus batch is due?  And if it will support neopixel strips?

Thanks!
-Jeremy

Offline jeremy.g

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Re: Jeremy.G's scratch-built Skywalker
« Reply #7 on: August 31, 2017, 09:18:31 AM »
I got the blade holder bored out for the 1" blade, with a hole in the bottom to fit an aviation connector so the blade will be removable.
That part was pretty straightforward.
In contrast, The "bunny ears" bulb holder arms are a serious pain in the butt.  Lots of assembly/disassembly/tweaking to make them fit.
If anyone else wants to attempt a scratch-built Graflex, I highly recommend simply purchasing repro parts for these components.

Then again, this may be one of the best ways to fit a 1" blade without the ears looking pinched.  Plus I'll have the secret pride in knowing that I own one of the only 'Graflexes" constructed from 100% stainless steel.  :)





Now I need a plan to flare those edges. . .


« Last Edit: September 25, 2017, 08:03:41 PM by jeremy.g »

Offline I am a Skywalker

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Re: Jeremy.G's scratch-built Skywalker
« Reply #8 on: August 31, 2017, 01:19:57 PM »
Lightsaber looks amazing so far, can't wait for the next update. I appreciate just how long it takes to do all the prep work and sizing having not started mine yet after about 10 weeks of research and still not feeling not I've gotten anywhere with many more weeks to follow no doubt XD
But a truly great looking lightsaber, keep up the good work and I'm sure the end result will look fantastic, its already looking very promising and I can see you're putting a lot of effort into it. The pictures and information from your saber build has really helped me get started properly too so thank you for that. Good luck on the rest of the build and good job :)
« Last Edit: August 31, 2017, 01:34:15 PM by I am a Skywalker »

Offline McAllister

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Re: Jeremy.G's scratch-built Skywalker
« Reply #9 on: August 31, 2017, 05:26:35 PM »
Seriously impressive work!


Offline jeremy.g

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Re: Jeremy.G's scratch-built Skywalker
« Reply #10 on: September 01, 2017, 07:43:15 AM »
Thanks for the kind words.  I'm new to the hobby and new to this forum, so wasn't sure how 'active' this board would be.
I'll keep updating :)

I.A.A.Sky- Let me know if you have any questions as I bang through this.  I'm sure there are better/faster ways to do some of this, but I'm happy to share how *I* did it at least!  (including the off-camera fumblings...)  Looking forward to seeing your project as well.

Happy Friday!

Offline EXAR KUN

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Re: Jeremy.G's scratch-built Skywalker
« Reply #11 on: September 01, 2017, 08:23:23 AM »
I love it!

Wonderful work with tremendous details. Keep going and good luck,

Offline jeremy.g

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Re: Jeremy.G's scratch-built Skywalker
« Reply #12 on: September 01, 2017, 11:48:57 AM »
Thanks Space!

Oh, and thanks for all your YouTube videos as well.  They've been a big help as I educate myself on choices for electronics and blade.

I plan to pull out all the stops on this one. . .

Offline I am a Skywalker

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Re: Jeremy.G's scratch-built Skywalker
« Reply #13 on: September 01, 2017, 01:39:40 PM »
Thanks for the kind words.  I'm new to the hobby and new to this forum, so wasn't sure how 'active' this board would be.
I'll keep updating :)

I.A.A.Sky- Let me know if you have any questions as I bang through this.  I'm sure there are better/faster ways to do some of this, but I'm happy to share how *I* did it at least!  (including the off-camera fumblings...)  Looking forward to seeing your project as well.

Happy Friday!

Thank you Jeremy.G that's very kind of you :)
I'd really appreciate it if you would be able tell me the diameter of the holes for the brass pins to go in on the front of the saber and how far apart you drilled the holes?
The tube I have has a 37/38mm (outer) diameter, just wondering if yours is the same/a similar size?
Thank you so much :)
As for the way you're making the saber I would say slower is better, that means its more likely to be more accurate than if you rush it and less likely to get anything wrong. So I would say keep going exactly how are you now, gives you time to think about the next step as well. And besides the slower methods certainly seem to be paying off :)
« Last Edit: September 02, 2017, 05:02:40 AM by I am a Skywalker »

Offline BEN KENOBI

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Re: Jeremy.G's scratch-built Skywalker
« Reply #14 on: September 01, 2017, 02:15:53 PM »
Love your work so far. it's amazing!! :huh:

 

retrousse