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Offline Sithblade

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My first saber build
« on: April 27, 2008, 09:04:47 AM »
Hi all

Just thought I'd post some piccies up, even though this one ain't finished yet.  I'm building a green K2 saber as learning project, and my next saber will hopefully be a LuxV, using some MHS parts and a CF board.  :)

I've used a thinwall blade, a few inches longer than on a regular FX, sink tube for the hilt, no sound board (might add one later though).  The K2 is being driven using a little current regulator I picked up but I think it would benefit from a Buckpuck.  I've got some parts coming that I'll be using to bling up the hilt, hopefully it should turn out well.

Despite it being a green K2 it's a Sith saber  ;)  That will become more apparent once the hilt is finished.

Anyway on with the build.

First job, solder the LED...  this took a few attempts, I've not soldered anything before but after a bit of practice I seem to be getting the hang of it. The scorch marks are from earlier soldering attempts!  I then epoxy'd the Lens / holder in place.



Next I put some epoxy on the wires coming back through the heatsink/mount to avoid any stress on the solder joins.  Also added a cable tie for the same reason.



Juiced up the LED to check it all works ok - dang these things are BRIGHT!!!





These are the parts I'm using for the hilt.  I've got a piece of sink tube which I cut at an angle using the bandsaw at work, I've then got some plastic water pipe which conveniently fits perfectly in the sink tube.  I'm going to cut a window out of this and use it to help keep all the wiring more snug, hopefully so things won't clatter around in the hilt.  Also the 4 x AAA battery pack is a bit 'lost' inside the sink tube as it is, so the reduced diameter of the plastic pipe will help keep it in place.



Groove cut out of the plastic tube - nothing pretty but it doesn't matter.



All the wiring is now in the plastic tray, I will go back later to tidy this up a bit more but as this is just a test fit it will do for now.



Let's check the electronics still work before we go any further...!!



Using a bit of foam to keep the battery holder in place.



Blade fitted in the alloy holder.  I hope to get a lathe soon so I can make parts such as the blade holder and pommels myself.



I've used a knurled thumbscrew I had laying around as the blade retention bolt.



Right, let's fire this bad boy up!  This piccy taken in my lit garage, under fluorescent lighting.





Right, time now for some comparison shots. I initially suspected that this saber is at least as bright as my brightest Force FX (a Luke ANH) despite the blade not being finished yet.  It currently contains just a few feet of cellophane.  I've got some Corbins film arriving next week, so the plan is to fit the corbins double-wrap then the cellophane inside that.  The few inches near the hilt are noticably brighter as is the last inch or so at the tip of the blade, but overall it's bright and pretty evenly lit.  I'm hoping the Corbins double-wrap with cellophane will even it all out further.

First piccy taken with my Luke ANH and Vader ANH for comparison.





Side by side with a single Maul...



The next three photos are taken on manual camera settings, 1/2 sec exposure, no flash and under the same lighting for a true comparison.

Single Maul...



Luke ANH...



My K2...



The Luke ANH appears better in photos than it actually is.  The blade colour, despite being a nice cobalt blue is actually quite flat but the camera doesn't pick that up.  Overall I'd say the K2 is about equal to the Luke on camera, however in reality it seems brighter.

Offline BEN KENOBI

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Re: My first saber build
« Reply #1 on: April 27, 2008, 09:34:12 AM »
 ;)
hello and welcome to the forum!!Congrats on your first home made saber!!Great job!! ;D

Offline Darth Venja

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Re: My first saber build
« Reply #2 on: April 27, 2008, 05:40:17 PM »
Great job! Nice, clean pommel and bright blade.  ;D

Offline darthmorbius

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Re: My first saber build
« Reply #3 on: April 27, 2008, 07:51:35 PM »
Clicky picky linky? ;D

Offline jpbeck

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Re: My first saber build
« Reply #4 on: April 27, 2008, 08:54:39 PM »
Nice-- welcome to the world of DIY---- Why did you go with a 4AAA over a 4AA? You have the room for the longer sled. Just wondering.
I like the sled idea-- no wires to twist on you. What are you using for a blade holder?
On that K2 Green-- it wants 700mA so if you push it with a 1000mA puck-- that thing will sting your eyes it'll be so bright.  ;D

Offline Sithblade

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Re: My first saber build
« Reply #5 on: April 28, 2008, 04:54:59 AM »
You should hopefully be able to see the larger piccies here:

http://s284.photobucket.com/albums/ll7/firestorm_996/K2%20Saber%20Build/

I went with the 3xAAA holder just because I had one laying around really.  Runtime seems to be good enough at this point but it's simple enough to replace it with a 4xAA if I need to.  The blade holder is just a basic alloy jobbie that's been machined up on a lathe, I didn't make that but hope to make my own in future when I get my lathe.  I bought it off someone here in the UK who had some saber parts spare.

I thought K2's needed 1500mah which would involve 2 x 700mah buckpucks in parallel?  I'll put rather put the money towards a CF board for my next LuxV  ;)

Offline QUI-GON JINN

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Re: My first saber build
« Reply #6 on: April 28, 2008, 08:57:19 AM »
Yes,  a K2 can handle 1500ma,  and two 700ma buck pucks are a lot less expensive than a CF,  and easier to get hold of as well.  It will look good on just one 1000ma buck puck as well.

BTW,  nice job on the first saber!


Offline jpbeck

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Re: My first saber build
« Reply #7 on: April 28, 2008, 09:27:33 AM »
You can run two 700's but IMHO there isn't much difference (to my eyes) between a K2 pushed with a 1000mA  and one pushed to 1400mA. FYI 
What's in store for this hilt?

Offline Sithblade

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Re: My first saber build
« Reply #8 on: April 28, 2008, 01:35:06 PM »
Aww heck, I can keep it in no longer...

I'm gonna use carbon fibre on the hilt, and some aluminium strip to act as a retainer lengthways up the hilt.  I've shaped the strip up already and my uncured carbon fibre sheet (so it can be moulded around shapes) has arrived today.  8) 8) 8)

Tied in with this is the need to relocate the switch further up the hilt, buy a different switch, and drill & tap holts in the hilt to allen-bolt the retaining strip to it.  But the payoff is it should look sweet.

The trick will be the join where it goes from CF back to sink tube.  I need to make a strip up to wrap around the hilt to cover the join and this will be a hard bit to get looking right.

I've not seen anyone use carbon fibre on a saber yet, and having had so many carbon parts on my bikes over the years it was an obvious choice of material to use.  I'd love to build a proper saber with a hilt entirely from carbon but (a) it's very expensive and (b) the hilt wall would need to ba around 3mm or more to avoid any flex.  Plus did I mention it's very expensive??!!