Jeremy.G's scratch-built Skywalker

[jeremy.g]

Thanks Ben!  The project has been a lot of fun so far.

Sky: I drilled 1/2" holes where the brass pins will be installed.
I actually used this template, which I stole from the internet:

http://switz.tripod.com/Template04.gif

I printed it out, checked the dimensions, and then glued it to my 1.5" pipe with CA glue so I could drill/grind/sand right up to the lines on the template.  It looks like 38mm is awfully close to 1.5", so I imagine the template should work for you as well.

[BEN KENOBI]

Thanks Ben!  The project has been a lot of fun so far.

Sky: I drilled 1/2" holes where the brass pins will be installed.
I actually used this template, which I stole from the internet:

http://switz.tripod.com/Template04.gif

I printed it out, checked the dimensions, and then glued it to my 1.5" pipe with CA glue so I could drill/grind/sand right up to the lines on the template.  It looks like 38mm is awfully close to 1.5", so I imagine the template should work for you as well.

I can appreciate  your love for this because when I build a light saber it's a labor of love!!

[Kanjiklub]

Very Cool!

[I am a Skywalker]

Thank you so much Jeremy that's really helpful, thank you for taking the time to get back to me. I was also wondering what length you made yours just to see if the length I was going to do for mine is similar? Hope the next stage is going well and I will be sure to keep checking on your post and seeing how the saber is coming along.
Should have some pictures to put up of mine soon when I start.

Update: Just been outside drilling the holes and cutting the end of the saber using the template you said about. Thank you so much once again for the help.

[jeremy.g]

Sky- Nice!  I hope your saber is off to a good start.

I just measured mine- its 10-5/8" (not including the D-ring mount).  I think I stole that measurement from a forum where people were discussing dimensions of actual Graflexes.

I had to put my own saber project (briefly) on hold this weekend.  I'll post the reason why in another thread... ;-)

[I am a Skywalker]

Thank you for all your help Jeremy, I'm very grateful. I may well have some more questions as you progress through the project XD
Good luck with the rest of the saber and on your daughter's.

[darthgrant]

WOW- this is insane......... Awesome!!!

[darthgrant]

Looks amazing... what tap size did you use to make the threads for the glass eye if I may ask?

[jeremy.g]

Hi DG,

The holes for the button and glass eye are tapped the same: 5/8 x 24. 

My reproduction button and eye came from "The Graflex Shop".  According to them, 5/8x24 is same as original.

Note:  If you use the same parts as I did, the glass eye will thread in smoothly, but the red button will likely need to be forced a bit.
Once the button is threaded in a few times (with padded pliers), the chrome will wear down slightly and will then thread in/out just fine by hand.

Hope that helps!

[darthgrant]

just ordered that same glass eye.......  now i have to try and pull that eye bump like you did.... time for experimentation!
and THANK YOU!!!

[jeremy.g]

Cool.  Good luck!  Glad to see there's another nut out there crazy enough to attempt this. 

Some notes on forming the bump: I tried several hole sizes in the 'forming' pipe.  7/8', 15/16', and 1".  I'm not sure what an actual graflex bump measures, but 15/16" looked best to me.  I used 1/2" hole for the 1/2" 'forming' bolt.  Forming the bump stretches the metal, and the hole becomes oval shaped- so I drilled the hole out round again with a 9/16" bit, into which the tap worked well.  I recommend trying all this with pipe scrap first. :)

Now that my daughter's saber is done, I spent some time on mine today.
I wrapped the bunny-ear arms around some 1" steel (same size as my blade), and made some collars that will wrap around the arms.
The idea is to clamp the whole thing in a vise.  The collars and rod should help the arms keep their shape wile I turn the edges over with a hammer.
I may use a little heat, which will help the metal move where I want it to.

It takes a silly amount of custom '1-off' tooling to form these bunny ears.  Again, I recommend just buying reproductions if the size works for you!

[jeremy.g]

It took some fiddling with a vise and tiny hammers, but I got the bulb holder about knocked out:


With 1" blade:


Not perfect, but not bad either.  Should look just fine once I file and polish a bit.

[I am a Skywalker]

Looking amazing, as usual, well done.

[jeremy.g]

I'm testing some bends and chiseled lines as I figure out the clamp...

[Thexter]

Very cool. When you do finish the clamp, I'd love to see how you did it.