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The Mining Colony: Home of approved FX-Sabers vendors => The Mining Colony - Archived Posts => Topic started by: ANAKIN SKYWALKER on April 27, 2013, 02:11:52 PM

Title: MR LE Count Dooku Conversion *finished*
Post by: ANAKIN SKYWALKER on April 27, 2013, 02:11:52 PM
You read that title right, it's an MR LE Dooku.  Not the fat hasbro fx saber.  I was going to wait till I was totally finished to post this, but it's coming along so well that I just had to share a few pics. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20130427-WA0004_zps5170f889.jpg&hash=ca71fa34f60af9c0f7520947bf2047b4676dae4a) (http://s1099.photobucket.com/user/agordon117/media/IMG-20130427-WA0004_zps5170f889.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F1d6f580f-9291-486c-829f-f8594edd7347_zps758f3fa5.jpg&hash=c3305bfa3826f31f5efeeca42535cf4a085ca6e8) (http://s1099.photobucket.com/user/agordon117/media/1d6f580f-9291-486c-829f-f8594edd7347_zps758f3fa5.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20130427-WA0002_zps21750340.jpg&hash=ece0f10f1b1919fc47cf214b998a040bc0c34551) (http://s1099.photobucket.com/user/agordon117/media/IMG-20130427-WA0002_zps21750340.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20130427-WA0007_zps8800fac9.jpg&hash=2890cbedb3f2f11982d27750e45294082a50f9ec) (http://s1099.photobucket.com/user/agordon117/media/IMG-20130427-WA0007_zps8800fac9.jpg.html)

There are a few pieces that need to be attached via JB Weld (like the one shown with blue tape) simply because there isn't enough room for 1138 set screws and wire passthroughs in the same space.  I was hoping to wrap this up this weekend so that I could get on with exam studying on monday but it looks like I'll have to trade my day off tomorrow for some shop time monday. 

One more thing, and I know it's going to happen anyway, DO NOT ASK ME ABOUT DOING MORE OF THESE.  I'm not going to get into the specifics, but I am only making 2 of these, and neither is being sold publicly.  These are simply too much work to do a bunch of, and that's only one of the many reasons that I will not be making any more. 

At this point, I have to make a pommel insert, and a new claw.  Other than that, it's pretty much ready for install. 

So?  What does everyone think?
Title: Re: MR LE Count Dooku Conversion WIP
Post by: jedicri on April 27, 2013, 02:15:22 PM
I never knew it was that thin!

Looks good so far.  Love to see final product.
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Goodman on April 27, 2013, 02:54:09 PM
Glad to see you're almost done, Alex! Your delrin brace idea was GENIUS, better than my wood ones. I'm sure your claw will come out great!  8)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Caine on April 27, 2013, 04:37:57 PM
Very cool, dude.  8)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 27, 2013, 04:46:01 PM
Thanks Goodman.  You were a huge help in this build and I gotta admit, you pushed me to be able to do the trigger buttons.  I'll be posting more build log pics when I do the second one (since I will be using all of the same braces and protectors) but I won't be doing a comprehensive tutorial.  This saber would be best as a crystal shard conversion, as it would not only save about half of the work, but it would also allow the stock screws to be used to hold the saber together (effectively solving the mystery of sd card access). 

For those keeping track, the curved section, elbow section, and grip section are cast aluminum, the pommel "wraparound" piece is machined aluminum, and the pommel, emitter, and grip ring spacer are machined brass.  Also, the rubber grips are fine, they are just not currently attached.  The 11 year old adhesive was ready to come off anyway, plus, it was necessary to remove them for machining the pieces.  I should also note that I'm at least 20 hours into the build at this point (though the second one should be a lot faster due to already having the protectors and braces for each piece). 

The saber will take a 3/4" blade, tri rebel (only a .65" light passthrough though to maintain strength of the machined coupler), 16340s, a CFv6, 20mm 3W speaker, 1.3mm charge port, and it will probably be sporting a brand new font some time down the road. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Scorpion on April 27, 2013, 05:10:53 PM
wow great work alex its great to finally see this thing, and i cant wait to see the finished saber...

love the dooku
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Gil Gamesh on April 27, 2013, 05:13:15 PM
Nice to see another big fish tacking the "un-convertible"  8)  Nicely done so far bud
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Scorpion on April 27, 2013, 05:18:14 PM
it really is small isnt it i didnt realize just how small, it looks tiny next to your hand
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Timo on April 27, 2013, 05:26:53 PM
Duuuuude!  That is insanely small.  Looks incredible though!  Job well done and good luck the rest of the way!   ;)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 27, 2013, 05:44:23 PM
I really fell in love with the saber because of the size.  I liked the EFX resin one more (in that one aspect) because the claw was mostly flush to the hilt and was thus even slimmer than the MR LE one. 

I haven't measured it, but I'd guess the typical diameter of the hilt is 1.1" and it gets wider at the pommel, spacer, and tip of the emitter.  I think the curved section is closer to 1". 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Goodman on April 27, 2013, 06:00:05 PM
You're most welcome, Alex, I'm glad I could help in any way. Like Kit said, the more impossiconverters we have, the better!

Have you decided which of the trigger switch layouts you're going to use? Either the plunger setup I mentioned (easiest), or a dual stage, hinged/stepped design?

In the latter, the forward part of the stock trigger is hinged (steel pin), and the Aux tactile is positioned at the mid point beneath the trigger, and the Main tactile is positioned at the rear point beneath the trigger. Finally, at the rearmost point of the trigger, a reverse spring loaded catch minimizes the total travel of the trigger, when measured from the forward point, to about 10 degrees. This keeps positive pressure on both tactiles. To activate the saber, squeeze the trigger all the way down to trip the Main tactile. During dueling, squeeze the trigger partially to only trip the Aux tactile. Match the config file to enable APOP accordingly, meaning full squeeze for activation, partial squeeze for Aux effects, and full squeeze PLUS partial squeeze to power off.

This is what I did on mine after trying the first method.
Title: Re: MR LE Count Dooku Conversion WIP
Post by: CHEWBACCA on April 27, 2013, 06:00:41 PM
awesome job AG
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Bruce Wayne on April 27, 2013, 06:06:38 PM
Great job, Alex.  It looks like it's coming along nicely.  And I'll reiterate everyone else's point: DANG! That thing's tiny!  :o

I'm sure you'll pull it off flawlessly when it's all set and done.  ;)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 27, 2013, 06:29:36 PM
I'm going with the plunger method.  it's a small concession to keep the little remaining sanity I have after this conversion. 

thanks everyone for the kind words. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: mre1207 on April 27, 2013, 07:11:58 PM
Wow that is tiny. You are like a vascular surgeon. Great work!
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 28, 2013, 09:29:15 AM
I have a pic (that I'm still trying to locate) of an MR LE Dooku in a lineup of hilts.  I'll upload it when I find it.  In the meantime, I've got the main led in place and the jb welded areas cured overnight. I used the jb weld to hold the emitter-curved section coupler into the emitter (set screw wasn't going to do it for me since the emitter is brass and very thin where the screw would have gone) and then I used a set screw to hold the coupler into the curved section.  I've wired and inserted the main led as well.

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20130428_112452_zps8debe357.jpg&hash=239bdd7797134de71fd63fb7c93652f209a48757) (http://s1099.photobucket.com/user/agordon117/media/20130428_112452_zps8debe357.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20130428_121720_zpsfd9c73b7.jpg&hash=e925a2370df6d8962f7885b999b1960c7d92c175) (http://s1099.photobucket.com/user/agordon117/media/20130428_121720_zpsfd9c73b7.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20130428_121725_zps9b797e4d.jpg&hash=9e23a648dcbd0af0bbb9eafe83096f45ab022ef3) (http://s1099.photobucket.com/user/agordon117/media/20130428_121725_zps9b797e4d.jpg.html)

The set screw hole is the one in the "middle"

One thing I've noticed is that every part on this hilt is not square.  The top and bottom slots on the emitter (for the claw and brass piece) are not 180* apart, and most of the surfaces aren't really flat against each other. 

Also, I don't currently have a 3/4" blade (working on that) or I would have done a bench setup with a blade in just for fun.  And the blade retention screw is going to have to be in the claw itself.  I don't see any way around it.  In theory, I could put it under the brass emitter greeblie but then I'd have to probably hollow out that greeblie a bit and somehow attach it in a way that is removable but will stay in place during "dueling".  I do plan on fighting with this hilt.  I'm not gonna go crazy, but I wanted to convert this hilt because of it's elegance and how comfortable it was to hold.  It would be a mistake to convert it and then only look at it through a mirror while wearing inspection gloves, lol. 

EDIT: Found the pic

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20121119_065621_zpsdbc04958.jpg&hash=42696ee79d99bc42e869fb4f1098a28c69411ba8) (http://s1099.photobucket.com/user/agordon117/media/20121119_065621_zpsdbc04958.jpg.html)

to the left of the vertical dooku is a parks 1" obi (which is very slender) and on the right is a JQ Ani.  The qui pictured is an MR LE with the remaining hilts being a replica graflex, my mkvi, and a jq QV.  It's not a good measure of the thickness of the hilt from this angle either.  The claw makes it look way fatter than it actually is. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Goodman on April 28, 2013, 11:58:38 AM
Use a 4-40 right through the claw for blade retention, you have the right idea ;). Also I may have good news about the waterjet file. I'll PM you tomorrow if it pans out. fingers crossed!
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 28, 2013, 12:19:09 PM
oh man, that would be awesome.   8)  it would certainly save me a few gallons of elbow grease.   ;D
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Darth Smorgis on April 28, 2013, 12:41:21 PM
Looks great Alex.  Cant wait to see the final product.  Keep up the great work.
I also had no idea that hilt was sooo thin  :o

Also, I havent forgot about those pics and review.  I am going to need a few days now though considering my current situation  ;)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 28, 2013, 12:43:45 PM
thanks man.  don't sweat it about the review.  heal up quick, but take your time with the review.   ;)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 30, 2013, 02:10:30 PM
Well, I put in a good few hours on this yesterday and today only to decide that my plan of attack wasn't good enough.  So I'm gonna let it sit until after exams and start fresh. 

the long version is that I wired everything up and realized my wire passthroughs weren't in the right places.  The wires had to totally wrap around the CF lengthwise and it ate up space that I couldn't give up.  So rather than try to rush through it and rewire it now, I'll wait until exams are over and just start fresh.  Stay tuned everyone.   ;)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: KingOfDathomir on July 28, 2013, 02:48:11 AM
Looks fantastic so far G. Man I thought that was one of those .45 scaled Dookus without the big ole claw on it -- thats way smaller than the Force FX versions !
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 12, 2014, 03:33:07 PM
Alright, so this is going to be my project that I work on while on my study breaks for the next few weeks, and I've got a really big update. 

First, I didn't like the direction I was going initially.  2 batteries just barely fit, and didn't really fit in a structurally secure way.  Since then, the 3.7v mod has become very common on builds, and with a single battery, I believe I will be very happy with the rigidity of the build, and I will be able to up the capacity of the cell.  I can fit a single 17500.  a 18500 would be pushing it, but if I was comfortable with really thin walls, a 18350 just might fit.  I'll be sticking with a 17500 though. 

I purchased 3 hilts initially in case this exact thing happened.  I had to be sure I could get 2 perfect ones, and for that, I wanted to take the pressure off by having a spare saber.  This gives me the freedom to change my mind about where I'm boring out the pommel (it will now be bored from the top of the "power cell" rather than the bottom), and little stuff like that. 

Second, there was always the issue of the claws.  I tried and tried to get a set waterjetted (goodman was going to have a set made up from a guy he knew, but I haven't heard from him in almost a year), but I could never find a place to do it.  So, it was going to come down to making them completely from scratch and totally by hand.  In the end, I gave in and did them.  And let me tell you, I'm glad I did. 

To refresh everyone's memory on this, a stock (accurate) claw cannot accept a blade.  It comes almost halfway up the emitter, so it would totally block any type of blade.  Bending the stock claw is impossible (not that it would produce good results anyway) as it just snaps when it would hit the bending point.  So, the first and most important step for a successful conversion of this hilt is to make a completely new claw. 

Now, since I didn't have a 3d model of this hilt on hand, I couldn't really make the claw so it just fit the blade.  I would have had to make quite a few of them to get it just off of the blade, but I didn't feel it was worth 20 hours of work just to get 3/16" closer to the blade with the tip of the claw.  It looks just fine to me as it is. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FMobile%2520Uploads%2FIMG-20140410-WA0027_zps2luynpwx.jpg&hash=8556773cf17c6525a07c729764e8dd4433a84e3a) (http://s1099.photobucket.com/user/agordon117/media/Mobile%20Uploads/IMG-20140410-WA0027_zps2luynpwx.jpg.html)
So, I traced the stock claw for the contour with pencil, and then shifted the claw so the front was out of the way, and sketched that section separately, then blended them together to come up with the final shape. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FMobile%2520Uploads%2F20140411_103459_zps5ktjpb4o.jpg&hash=72b0925365131d70f82019134346548e5621d9f6) (http://s1099.photobucket.com/user/agordon117/media/Mobile%20Uploads/20140411_103459_zps5ktjpb4o.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FMobile%2520Uploads%2F20140411_154216_zpselorrrmh.jpg&hash=0cd47ae28f43d175cebb88b91ca7feca54ca57d3) (http://s1099.photobucket.com/user/agordon117/media/Mobile%20Uploads/20140411_154216_zpselorrrmh.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FMobile%2520Uploads%2F20140411_164220_zpsuftr63pu.jpg&hash=9afe316c21eecca5184508b17c607ca775309341) (http://s1099.photobucket.com/user/agordon117/media/Mobile%20Uploads/20140411_164220_zpsuftr63pu.jpg.html)


(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FMobile%2520Uploads%2F20140411_165021_zpsszqwo48d.jpg&hash=ef3db1920849261036cb118f4707f7a99567c94d) (http://s1099.photobucket.com/user/agordon117/media/Mobile%20Uploads/20140411_165021_zpsszqwo48d.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FMobile%2520Uploads%2F20140411_173403_zps3ozwz4ke.jpg&hash=362b3b12c716d405d89fdce7dc9c1e32bc386aa7) (http://s1099.photobucket.com/user/agordon117/media/Mobile%20Uploads/20140411_173403_zps3ozwz4ke.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FMobile%2520Uploads%2F20140411_173417_zpsbbwhlirs.jpg&hash=805e499f47d1e65b206d5b94c573b677b0107ee3) (http://s1099.photobucket.com/user/agordon117/media/Mobile%20Uploads/20140411_173417_zpsbbwhlirs.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FMobile%2520Uploads%2FIMG-20140411-WA0017_zps0mlohhi6.jpg&hash=5281ac939658be8332d88789e1fe82dc242b5ea5) (http://s1099.photobucket.com/user/agordon117/media/Mobile%20Uploads/IMG-20140411-WA0017_zps0mlohhi6.jpg.html)
this one shows how the blade will fit in relation to the claw.  The hilt is not "assembled" so it may be skewed in other pictures. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140412_174816_zpsh3oaf5ap.jpg&hash=5531031534426176656e25e211c88b1d0678c235) (http://s1099.photobucket.com/user/agordon117/media/20140412_174816_zpsh3oaf5ap.jpg.html)
This shows approximately what the final finish of the new claws will be.  It matches the chrome very nicely. 

That's all there is for now, but just so everyone knows how hard it was to make these claws, I had to use a mill to thin the stock, a bandsaw to rough cut it out, a belt sander to rough shape it, a mini pneumatic rotary sander and dynafile to finish shape it, some triangle files for the cutout in the claw, and then finish it with sandpaper and a buffing wheel.  I had to make 3 claws as one came out a little thin, but the two "final" ones are perfect IMO.  I'd give them a 9.5/10.  Each one took around 4 hours of shaping and so far, I've spent about 3 hours finishing, and I'm only about 1/3rd done finishing the first claw. 

I have to order a 3" x 3/16" endmill and something close to a 51/64" endmill (closest I can get to .790", but above).  Other than that, a piece of machinable polycarb or acrylic (for the switch plungers), mini 2w speakers, and the new batteries, I have everything I need to finish these up. 

EDIT: I also want to make it clear, I am not just dusting these off because of the korbanth run.  I did not have the same skills at freehanding stuff when I started these as I do now.  As a result, I was absolutely not going to make the claws by hand.  Since then, however, I've gotten dramatically better at freehanding parts, and I think that shows here.  I've been meaning to pick these up since before the duke run was announced (probably about a month before), but unfortunately, have been too busy with commissions and school to do it.  Well, now I'm finally ready to dust them off, and the timing just happens to coincide with the run. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: RyDiddy on April 12, 2014, 04:25:56 PM
Looking great dude. Fantastic work as usual.
Title: Re: MR LE Count Dooku Conversion WIP
Post by: bombarta on April 12, 2014, 05:59:05 PM
Can't wait to see this finished.
Has randys duke run given you a little push of motivation?   :P
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 12, 2014, 08:10:52 PM
Nope, no motivation came from the dukes.  I have a chance to hand off a saber to juan in person coming up, so I assessed what I have here, and that was this was the closest to completion.  I've been trying to do these for a looong time, and finally after my last attempt to get the claws waterjetted fell through, enough was enough, andthe timing was purely coincidental. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: CHEWBACCA on April 12, 2014, 09:44:11 PM
That turned out great Alex. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 13, 2014, 07:06:36 AM
Thanks man.  I'm hoping to put 1-2 hours per day into this until it's done.  Hopefully, I can get the rest of the parts that I need ordered and wrap these up. 

Oh yeah, these will still have cfv6s because I have had the project sitting for so long. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Justintmars on April 13, 2014, 08:38:09 AM
Looks amazing so far!
Grade A saber Art my friend  :D
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Scorpion on April 13, 2014, 09:59:14 AM
looking good Alex but should the blade be so far away from the tip of the hook?
great 1st attempt however
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Wildcard on April 13, 2014, 10:04:08 AM
Looks great so far; nice progress on your project!
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 13, 2014, 10:09:15 AM
Thanks!

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140413_111359_zpsxcpzuv1h.jpg&hash=7966eb6a9e7a59e463b0b4c4d609c12977aaa3c2) (http://s1099.photobucket.com/user/agordon117/media/20140413_111359_zpsxcpzuv1h.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140413-WA0004_zpsmlwujc6v.jpg&hash=6ce5030e650fbac63a035c1a695c32fcc118aae1) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140413-WA0004_zpsmlwujc6v.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140413-WA0006_zpstcjh6seq.jpg&hash=55e5a504f2e475024ac3df09baf3fe470a5281e2) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140413-WA0006_zpstcjh6seq.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140413-WA0008_zpsrufrruk9.jpg&hash=4eec51de186351d29f36164df9805feafdae7614) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140413-WA0008_zpsrufrruk9.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140413-WA0010_zps2lhzxqyo.jpg&hash=1abe93bf6e4e7b92c6e8cbd6b4616d019a9b2d6f) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140413-WA0010_zps2lhzxqyo.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140413-WA0012_zpsj0fhuicl.jpg&hash=592932772afc5c427a87bc5f934dc5f5fae9b231) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140413-WA0012_zpsj0fhuicl.jpg.html)

So, as you can see, I took my 2 hours today to bore out emitter #2 and pommel #2.  By changing my method of boring for the pommel, I get to keep the "signature edition" label across the bottom on the pommel not shown, and I can have totally hidden sound holes.  The depth of the bore should allow me to have some really nice resonance, so this saber should be actually quite loud.  I will make and polish an insert that makes the pommel look totally stock, which actually won't take much since it already is very difficult to see the bore in the pommel.  The silicone tape wrapped around the pommel when it was in the lathe chuck is to protect it from the jaws (which it did perfectly). 

Also, given that my mill has a digital readout now, I can tell you exactly how far off center the blade is.  The number is .0120" above center.  We'll see how that translates when I make my blade plugs.  I may have to compensate or I may not.   If I would have gone exactly on center, the emitter would lose any chance of structural rigidity as it would no longer have been a complete piece. 

looking good Alex but should the blade be so far away from the tip of the hook?
great 1st attempt however

I already explained that above.  I'm not going to just make a bunch of claws until I hit on the exact shape.  20 hours of work isn't worth 3/16" closer to the blade.  It's 100% inaccurate no matter what just by holding a blade, so I'm not really going to worry that much about how close the tip of the claw is to the blade. 

If someone did a run of dookus, they could base the exact distance of the claw on their existing 3d models, but there wasn't a good way to manually draw up the claw in relation to the blade, so it would have taken at least 2 more attempts (bringing the number of total claws to 5) to get it barely off of the blade.  It isn't just the distance from the blade that would have had to be changed, but the angle at which the old claw shape (that fits the body) and new claw meet. 

The shape of the tip is accurate though.  It just come off of the hilt at a slightly different angle than the stock one. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Dark Navel on April 13, 2014, 10:43:31 AM
I'm really impressed to see what you have done with the MR version of the Dooku.  Your design and implementation are impressive.  I look forward to seeing the finished product.  Nice job!
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 13, 2014, 12:19:47 PM
I'm really impressed to see what you have done with the MR version of the Dooku.  Your design and implementation are impressive.  I look forward to seeing the finished product.  Nice job!

Thanks!

This is already my favorite build ever, and I haven't even finished it.  The hilt is just soooo nice.  I measured the main grip section (which is wider than the curved and elbow pieces) and it's just over 1.2", which makes this one of the slimmest sabers I've ever handled.  With the switches in the trigger, it is also one of the most natural to operate. 

Making a note to myself here, I need to make some covertec clips out of aluminum for this.  I can buy some, but I really like the flat black powder that I have for covertecs, and to powdercoat one, I need to machine it differently than the ones from tcss.   

EDIT:  I was just going to take apart the second pommel, but wound up right next to the lathe, so I spent 15 minutes boring it out.  Here's the pair together.  One hilt is an SE, but I have no Signature plaque for it unfortunately. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140413_171349_zps80yxm9lt.jpg&hash=0c7dd8f947eed952801947c8f1ae416627086f5d) (http://s1099.photobucket.com/user/agordon117/media/20140413_171349_zps80yxm9lt.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140413_171359_zpsxys7tuei.jpg&hash=960834ac5f19872928bad00d7ae5f6dafd5964b6) (http://s1099.photobucket.com/user/agordon117/media/20140413_171359_zpsxys7tuei.jpg.html)

as you can see, the bottoms of the pommels are untouched, which is really nice for the SE hilt.  It looks like this is progressing quickly, but the cake is a lie.  I wrote up a list of what really still needs done, and it's huge.  I'm 25% done if you include making the claws. 

Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 16, 2014, 01:07:15 PM
had a rough day on these yesterday.  Everything is turning out great, but they just fought me in the shop yesterday.  literally, a fistfight.  Moral of the story, if one of you really does wish to do probably the hardest conversion ever (I've never seen a harder one, but there may be one or two that are tied), and you manage to get all of the screws out, do not put them back in under any circumstances.  The screws are epoxied in, and they have heads that are harder than all of my screwdrivers, so they just chew right through the driver heads.  But, each time they eat one up, the corners in the screw get slightly rounded.  It is usually possible to get it out once, but I simply could not get the screw back out the second time on one of the hilts.  So, a snapped drillbit, snapped endmill, and many hours of cussing later, I did manage to get everything sorted out.  However, in the process, the very weak paint (the elbow section isn't media blasted like it should be, it is painted that color) peeled, so now I have to either media blast it or powdercoat it (in blasted steel or aluminum color) depending on if the media blast will tarnish over time.  All easy stuff for me really, just adding time to the build, and in the end, durability. 

So, once I got that sorted out, I came up with a new method for holding the elbow section to the main body.  I won't show it yet since I didn't create it at this point, but it is much better than the stock way IMO. 

Also, I was having a chat with my buddy scorpion, and explaining how there isn't a really good way to hide a charge port on this hilt, and he suggested something that I honestly had not thought about.  A covertec charge port.  Now, I had thought about it briefly, but my mind couldn't get out of 1.3mm mode, so I immediately threw that out the window.  But, looking at the hilt again, there is just enough room to hide a 2.1mm charge port in the covertec.  I just made a setup like that 2 weeks ago, and it turned out perfect.  I should definitely be able to do it again here.  This wasn't really feasible originally since I didn't have the capabilities that I do now, but it also wasn't a good idea with a 2 battery setup.  With a single cell, it will work perfectly. 

Next up, I figured out how to remove the triggers, so now I can make it "touchplate activation" rather than having switch plungers.

So, these hilts should have 0 visible holes between the pommel and elbow connector.  In fact, the only visible holes besides the bladeholder are the 4-5 that will be in the claw to hold everything together and for blade retention (also in the claw and included in the 4-5 count).  I "could" limit that to 2 if I really wanted to, but I only would have had 2 options for that. 

#1, I would have had to buy special bottoming taps, and drill partial holes from the hidden side of the claw and tap them.  Then, I would have had to drill matching holes in the grip section (under the knurled rubber) so I could secure the setscrews without them being visible.  If at a later date, replacement claws were made or these ones were sent to be chromed (which I doubt, but I like to leave it open), it would require a total uninstall of the saber to do so.  Given that one is going to mexico, I'd much rather juan be able to remove the claw himself if need be. 

2nd, I could have used a bunch of jb weld.  Not removable at all.  There are places (well, actually just one I can think of) where I will have to use JB weld on this build, but I didn't want that to be one of them.  When something is cnc'd from scratch, sure, you can plan for screws or threaded pieces everywhere.  But, when converting a solid saber like this, sometimes there is no avoiding it. 

Title: Re: MR LE Count Dooku Conversion WIP
Post by: Caine on April 16, 2014, 09:29:24 PM
Very cool! Things are just getting more and more impressive with this.
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 17, 2014, 07:32:08 AM
Thanks!  I am really loving the way this is turning out, and i'm 100% confident that it will withstand duelling.  Obviously, it is a 3/4" blade, but anything that can take, the saber can take. 

One of my special endmills for this build arrived yesterday and the other should arrove today.  I would like to at least have the upper half of the hilt (forward main grip, trim ring, curved section, and emitter) totally done this weekend.  That will leave me with the new coupler between the grip and elbow section, the finishing of the elbow, and a lot of modifications to the elbow section and the pommel wraparound piece. 

I'm taking it slow and not expecting to finish before exams.  If I didn't have a test on tuesday, i'd spend all weekend cranking these out, but this is one of those final tests before the actual final exams that the professors love throwing at us this time of year. 

Stay tuned everyone!
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on April 19, 2014, 02:26:06 PM
Alright, so my new batteries arrived today, and I'm happy to say everything is going better than expected.  The 16430s I have are 16.5mm in diameter, and the 17500s I have are like 16.9mm, which is really good for my wall thickness of the hollow coupler between the curved section and the main grip. 

Both of my special endmills are here, and I put them both to good use already.  The CFs fit perfectly with just a slight layer of material removed from either side of the inner grip. 

Unfortunately, my predictions about bead blasting the elbow sections turned out to be correct.  The aluminum turns very dark very quickly (I haven't held the parts since I got home with them yesterday, and they are already 300% darker than when I freshly did it) and the media in the machine at the big shop is a bit too coarse.  The color matched very well when it was fresh, so I'm going to just order the media blasted aluminum powder coat color and redo both elbows with that.  It will be much more durable and will probably look better since the paint on these was 12 years old.

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140418-WA0003_zps0x4wj7c8.jpg&hash=b65032c2605c3812774bef7482431933dee1ad3d) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140418-WA0003_zps0x4wj7c8.jpg.html)
left is fresh off of the bead blaster vs the original paint on the right.  The color is correct, just not the texture. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140419_105152_zpsbwspeszp.jpg&hash=03ded9e55e5a82c87fdcabc425e068397ae6ad5c) (http://s1099.photobucket.com/user/agordon117/media/20140419_105152_zpsbwspeszp.jpg.html)
CF nestled in place.  You can faintly see the spot where I widened it.  It's hard to make out next to the original epoxy, but it is in line with the upper half of the open hole in the side of the hilt. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140419_140331_zpsd3pah0rd.jpg&hash=55ba1b7ac546d151f6820c64276734d0e945f302) (http://s1099.photobucket.com/user/agordon117/media/20140419_140331_zpsd3pah0rd.jpg.html)
I was making this piece before my batteries actually arrived, and they showed up just in time for me to take the last pass.  It has less room than it looks like.  A standard size wire from erv will just fit next to the battery. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140419_141214_zpsahheb8ka.jpg&hash=b91a10aa9d50917faed564565ac5df8725d71c3d) (http://s1099.photobucket.com/user/agordon117/media/20140419_141214_zpsahheb8ka.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140419_141222_zpsgdjud9hi.jpg&hash=df8a9528b9b955a782ecb67cedd971e49f81adaa) (http://s1099.photobucket.com/user/agordon117/media/20140419_141222_zpsgdjud9hi.jpg.html)
whatever kind of adhesive they used for the grips did a great job of sticking to the chrome, but a terrible job of holding the grips.  Not one grip has even one speck of adhesive on it, which is a good thing I guess, but i literally cannot get any more adhesive off then I did. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140419_171947_zpsmlv1aicf.jpg&hash=deb26ab8f2b204e5c4921342509d956f92fe620a) (http://s1099.photobucket.com/user/agordon117/media/20140419_171947_zpsmlv1aicf.jpg.html)
The saber is holding together by itself here, but still needs a new coupler between the main grip and elbow section, plus a buttload of mods to the elbow. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140419_172005_zpszgvwtkob.jpg&hash=17bc9e7ec879a816f74f505876b1a67f85bcc047) (http://s1099.photobucket.com/user/agordon117/media/20140419_172005_zpszgvwtkob.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140419_172017_zpsfnem3rjx.jpg&hash=d77f7883454fed7afb4ac5fd840bf3de00cd1f75) (http://s1099.photobucket.com/user/agordon117/media/20140419_172017_zpsfnem3rjx.jpg.html)
the setscrew is final, the socket cap screw is temporary. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Justintmars on April 21, 2014, 12:49:32 PM
Beautiful work Alex!
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on July 24, 2014, 11:54:05 AM
so, I found myself with some extra time while waiting for some parts to arrive for other builds, and I decided to dust these off yet again.  They were interrupted by exams and whatnot, but I finally was able to get moving on them again. 

I already knew from the moment I decided that I wanted the charge port and switches to be hidden that the elbow section of this saber was going to be the part with the most machining hours that I've ever done, and man was I right (I hate it when I'm right, lol). 

First up, the tab that goes into the pommel snapped while I was doing some machining (it was a great vice point while it held together).  I wasn't really surprised because it was pretty thin, and the part is cast, so it is pretty weak at thin areas like that.  So, I had to mill out that whole section so that I can make a new pommel coupler.  That took about 3 hours because I had to grip it very carefully in the vice, and only take layers of about .025" at a time.  (https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140721_155153_zpslpbhak43.jpg&hash=a77e89f2e2edde0ddef3bd8e05e1fb66ead57ca3) (http://s1099.photobucket.com/user/agordon117/media/20140721_155153_zpslpbhak43.jpg.html)



Next up, I re-clamped it, and drilled and tapped for a recharge port to fit through the covertec.  This would require that the whole elbow section be hollow, so I re-gripped it a 3rd time (with some custom wood vice protectors I milled) and got to work on that.  Again, only passes of about .025" in depth to be sure nothing would give way under the mill bit or the vice.  (https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140723_145544_zpsvxs1ujcw.jpg&hash=d06e05a77dafcfec62826ebe816b8e325f772fa7) (http://s1099.photobucket.com/user/agordon117/media/20140723_145544_zpsvxs1ujcw.jpg.html)



Then, I flipped the section over, and started milling out the trigger area.  Now, I only had a 3/16" bit that was long enough to mill through the material without destroying the edge of the piece, so the sharp corners had to be done with a hand file at the end.  That wasn't even the interesting part.  Because of the way I had it gripped in the vice, I knew I couldn't cut the full slot or the piece would snap in two.  So, I stopped about .25" short of the full length of the trigger slot, and brought the slot the rest of the way out with hand files.  Even when you really know your machines, you still have to do some things the long way. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140723_152133_zpskjcaqi75.jpg&hash=344e5c74a018f76e1a5a9264c26892a5cc20f481) (http://s1099.photobucket.com/user/agordon117/media/20140723_152133_zpskjcaqi75.jpg.html)
you can see here that the slot stops where there had previously been a step down.  that's where I hand filed from and brought it to full length. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140724_141946_zpszerz9q0s.jpg&hash=42757027776135d3b59da34b3ac4147417b91881) (http://s1099.photobucket.com/user/agordon117/media/20140724_141946_zpszerz9q0s.jpg.html)

I also didn't like the way the elbow piece attached to the main body of the saber, so I got to work machining a better coupler.  there will be just enough room to remove an sd card with some sharp tweezers, and it will be much more rigid when assembled than it was from the factory.  I used brass for the piece to help balance out the weight I removed, but the male coupler itself was made from aluminum.  (https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140721-WA0040_zps0z8onvou.jpeg&hash=06ac53255eb4b49a3a18c3aa7476778b05e6a2ad) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140721-WA0040_zps0z8onvou.jpeg.html)
(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140721-WA0045_zpslngctgvx.jpeg&hash=90d27557684713f780cbe5536164022fd631f869) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140721-WA0045_zpslngctgvx.jpeg.html)
had to hand drill the wire passthrough after I milled the hole for the male coupler piece. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140724_141953_zps6vdbsfhp.jpg&hash=0cad2584188a233285fa42c50ba9164fc9d2793e) (http://s1099.photobucket.com/user/agordon117/media/20140724_141953_zps6vdbsfhp.jpg.html)

came out pretty dang good considering the surface I was drilling on had a 15 degree slant. 

I have figured out my switches from here, and the only thing I will lose on this saber is mute on the go.  The trigger will be hinged in the middle, so you would be unable to press both the aux and main buttons at the same time.  if I made my hinge point spring loaded to allow both to hit if you wanted, it would probably add 20 hours of machining just for the ability to activate mute on the go, so I think I'll pass on that one for this saber. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140724_141102_zpsk7ki9auk.jpg&hash=09319146ab2529bdeddead0e15ab9d97d5effcd0) (http://s1099.photobucket.com/user/agordon117/media/20140724_141102_zpsk7ki9auk.jpg.html)

Also, the only visible imperfection at this point is the alignment of the screws in the claw.  Every time I would start another hole, I would line it up perfectly, make sure everything was set, center drill it, and then drill and tap it.  Well, I didn't realize it until the 3rd hole, but the claw itself would flex a hair toward or away from the operator when it was being drilled, so 2 of the holes came out slightly misaligned. 

Finally, I milled off the brass greeblies that are in the elbow section since there was not going to be a way to mask them for powdercoating.  Fabricating new ones will take about 10 minutes each on the lathe. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140724_142044_zpskfg96k6p.jpg&hash=71a11c06f8c4a8eaf985f83fc3817b5698fd3c6b) (http://s1099.photobucket.com/user/agordon117/media/20140724_142044_zpskfg96k6p.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140724_142008_zpsjwu4hvlq.jpg&hash=e129af3416cc90ef3da2a5580f0784915fcaa162) (http://s1099.photobucket.com/user/agordon117/media/20140724_142008_zpsjwu4hvlq.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140724_141941_zpsnxyyvhex.jpg&hash=26b6f089578f040d647303e15caf750d51e7c46a) (http://s1099.photobucket.com/user/agordon117/media/20140724_141941_zpsnxyyvhex.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140724_141935_zpsskjbukvy.jpg&hash=3dfed03693da84c11d1fb13f6fcfefb5d5c5d625) (http://s1099.photobucket.com/user/agordon117/media/20140724_141935_zpsskjbukvy.jpg.html)

some nice before and after shots there.  But here's a better before one showing the old coupler. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140721-WA0036_zpst8cqanv0.jpeg&hash=16005ce75a7a013fa64c5366af6963fc8d291590) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140721-WA0036_zpst8cqanv0.jpeg.html)

My only hiccup so far has been my powdercoating.  The powder didn't seem to set correctly, so I will have to blast it and re-coat it after I try this color on a few test pieces (duh, should have done that first.)

Overall, I spent about 18 hours on just that elbow section this week.  And I still have a very complex piece to make to attach the pommel and I have to make a cap to cover the removed material before the rubber grip goes on. 

oh yeah, you might notice I didn't smooth out the walls of the sections I milled after I got to the proper depth.  Since they will be hidden anyway, I didn't feel the need to risk the part or the tool by putting that kind of pressure on a smoothing pass for the walls.

Title: Re: MR LE Count Dooku Conversion WIP
Post by: Justintmars on July 25, 2014, 02:18:38 PM
Your skill and dedication is extremely inspiring Alex...
Title: Re: MR LE Count Dooku Conversion WIP
Post by: GusManB on July 25, 2014, 02:58:52 PM
Vary nice jobs thus fare on this, looks shiny ;)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on July 28, 2014, 12:37:47 PM

Started with a piece of bar stock this morning to make the trigger pivot holder and the pommel coupler.  You can see in one of the shots the new vs the stock, and that mine is much smaller in one dimensionn. That was by design, to allow for some sound venting.  So far everything is going very smoothly. 

There are really only a few operations left on the machines before I can begin my install.  Should have more progress to share tonight. 


(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140728_101442_zpsopuy253i.jpg&hash=f75e7ef699102c885abefdb47e3a0c030ff00ec9) (http://s1099.photobucket.com/user/agordon117/media/20140728_101442_zpsopuy253i.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140728_115542_zpswxbhcqdj.jpg&hash=e3d773a743b02d9c00fbe7bc6b4e015e31d5d17a) (http://s1099.photobucket.com/user/agordon117/media/20140728_115542_zpswxbhcqdj.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140728_123603_zpsdqmmqrvq.jpg&hash=9d560edb5fdd90f7a0eedf1a64b65bf1869a9bfb) (http://s1099.photobucket.com/user/agordon117/media/20140728_123603_zpsdqmmqrvq.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140728_132227_zpsthy8jjhr.jpg&hash=c25ca343ea57c229310dedd70918e7369c847837) (http://s1099.photobucket.com/user/agordon117/media/20140728_132227_zpsthy8jjhr.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140728_134413_zpshuimbsdb.jpg&hash=a72dd14a383b54046e5fcdf4a41958e1a961903e) (http://s1099.photobucket.com/user/agordon117/media/20140728_134413_zpshuimbsdb.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140728_134714_zpsydz2ctwr.jpg&hash=e7f7648bf2ae013a8a32765c1603e205ebda6e54) (http://s1099.photobucket.com/user/agordon117/media/20140728_134714_zpsydz2ctwr.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140728-WA0011_zpsabn3num6.jpeg&hash=d858511c4801eeb99800d81803f5fb1ed83af402) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140728-WA0011_zpsabn3num6.jpeg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140728-WA0013_zpsmdotni2u.jpg&hash=9d8dc75e8cf1d5d4e2ebf052e05d276114877970) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140728-WA0013_zpsmdotni2u.jpg.html)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Clark Kent on July 28, 2014, 12:48:35 PM
looking good man, so close, so close to being done.

this makes me wish i had mine finished too.

right now mine is waiting for installs.
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Ho-Wai Lowill on July 29, 2014, 12:44:21 PM
Wow, this is seriously an amazing built, well worth the effort and with all that heart putting in itz definitely gonna be epic when finished.
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on July 29, 2014, 01:09:22 PM
thanks guys.  I did a smidge of work on this today, but I'm at the point where I need to do 6 steps that all have 6 hour cure times, so I am creeping forward slowly on this.  I did put the blade into the assembled saber this morning and man was it beautiful. 

so, at this point the powdercoat is stripped and I'm jb welding the new pommel coupler into the elbow section.  Once that cures, I can re-powdercoat and then jb weld the pommel spine in place.  The pommel is held on by a screw (which also holds the elbow to the pommel spine) but it is so loose that I don't trust it to hold everything in place correctly.  with the jb weld holding the spine, everything sits much nicer.  MR actually had everything epoxied, so it was really designed to be done that way.  I'm just doing it that way better.   :))

should have some more progress on this tomorrow at some point. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Pinousse on July 29, 2014, 01:17:36 PM
Just stunning  :o No words  :o
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Darkjedi on July 29, 2014, 04:03:08 PM
This is truely complex. This is an amazing build
Title: Re: MR LE Count Dooku Conversion WIP
Post by: scottjua on July 29, 2014, 05:53:30 PM
I have an mr Le  I bought just for this but seeing your build I don't seee having time for it any time soon. Guess I should just sell it. That build defeats me. Lol

Looks fantastic Alex. Can't wait to see it done.
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on July 30, 2014, 09:36:53 AM
Thanks everyone.

@scott, tell me about it.  If I had known what this would have taken, i'm not sure I would have done it. 

Anyway, I cut the setscrews to length, powdercoated the elbow again, and assembled it for a few test swings.  Man this thing is super comfortable and fluid to use.  I need to shave down the pommel coupler a little bit on the mill (the pommel isn't quite centered because it is a hair too thick) and then jb weld the pommel spine to the pommel coupler.  Once that's curing, I can begin the machining of the pommel insert, the brass greeblies, and place the led and battery in the upper half of the hilt.  From there I can machine the trigger rocker, and then start wiring. 

At this point, i'm unsure if I am even going to make blade plugs.  This bladeholder is such a perfect fit for my blade, that I don't need a setscrew.  If I want a blade plug, I will need a setscrew.  It would be a very akward setup on the mill, so for now, I will skip it.  In reality, I can always add one later if I feel that the saber is missing slmething without the blade plug, but it looks just fine to me without one. 




(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140730_121416_zpsamgkoob_edit_1406737624047_zpshgna8vcs.jpg&hash=cc5d9dec67dce56647b33b42c707540febed6267) (http://s1099.photobucket.com/user/agordon117/media/20140730_121416_zpsamgkoob_edit_1406737624047_zpshgna8vcs.jpg.html)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on July 31, 2014, 06:02:24 PM
(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140731-WA0026_zpswebuzybw.jpg&hash=fb600f4c908e49fcb043d6c518cc09a1d27a2142) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140731-WA0026_zpswebuzybw.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140731-WA0024_zpsonmlnxku.jpg&hash=391e2632d91aa48fe79f11ea24e5bede402bc66b) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140731-WA0024_zpsonmlnxku.jpg.html)


Moving right along on this.  All of the wires are strung through, the switches are installed (and freaking sweet).  I literally cannot stand up hunched over my workbench for another minute, so i had to call it a night before i wrapped up the install.  I'll finish tomorrow assuming i get the covertec knob and pommel insert machined in the morning. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: scottjua on July 31, 2014, 08:30:07 PM
I know that feeling... Looking great man. I will concede defeat though... I don't even want to get into that build.

Hahaha... MR LE Dooku going up for sale soon.
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Pinousse on August 01, 2014, 12:29:04 AM
Stunning.... Can't wait to see it done :)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on August 01, 2014, 05:03:25 AM
Thanks guys.  Up early this morning to try an wrap this up before I leave for the weekend.  Stay tuned for more progress. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Pinousse on August 01, 2014, 06:33:51 AM
 :D
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on August 01, 2014, 07:28:07 AM
(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140801-WA0005_zpsbo8ze2zn.jpg&hash=0bd114a5222567c8d6cbab21a4f497a2d1a828ed) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140801-WA0005_zpsbo8ze2zn.jpg.html)

IT... IS... ALIVE...

And, unlike last time I attempted the install, I know that everything is going to fit before I start shoving everything in.  The CF was such a tight fit originally that I had to push way harder than I should have to put it in place.  Well, that was over a year ago before I had enough machine experience to do this build the right way (like I am now).  Things are going very smoothly.  More to come throughout the day. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Greebles on August 01, 2014, 07:45:40 AM
This has to be one of the most complicated builds I have seen. Great job.

-Denzil
Title: Re: MR LE Count Dooku Conversion WIP
Post by: scottjua on August 01, 2014, 07:46:35 AM
Nice! Do you think there's any way 7/8" blade is possible?
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on August 01, 2014, 07:54:11 AM
A 7/8" blade would not fit.  The emitter is milled out to accept the claw, and with a 3/4"  blade, maybe even slightly off center to compensate for said milled slot, I only have about  .020" of thickness where the claw is. 

Maybe a cnc'd stainless steel version could have a 7/8" blade if kt was done just right.

I mentioned my 3/4" blade "may" be off center to compensate, but I cannot actually tell.  A 7/8" blade off center would be extremely noticable. 

And, this cannot be bored on a lathe without ruining the parts (besides the pommel).  Has to be all millwork, which is tough considering the MR is not square to anything.  I used up a whole years supply of elbow grease making my cuts straight. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Pinousse on August 01, 2014, 08:54:27 AM
So awesome saber... Good job!  :D
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on August 01, 2014, 12:12:03 PM
so, I ran out of time today, but made really good progress.  Trying to upload some pictures but the upload won't trigger on my phone for some reason (done it already today, so idk why it won't start). 

at this point I just need some epoxy to hold the speaker in place and I'm good to go.  the hilt is running on its own battery.  everything is in place and man this is wrapping up nicely.  I'll be able to wrap it up on monday so everyone sit tight.   :))

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140801_150321_zps3bzmhydq.jpg&hash=f43ce64ab3419bb4723601feccf551c88c3af05c) (http://s1099.photobucket.com/user/agordon117/media/20140801_150321_zps3bzmhydq.jpg.html)

here you can see the cover for the milled out area on the elbow section. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140801_150317_zpsz5pcisrj.jpg&hash=e5feeb8020c5bec117ab94d838a1909f30d1ed57) (http://s1099.photobucket.com/user/agordon117/media/20140801_150317_zpsz5pcisrj.jpg.html)

illuminated on its own. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Scorpion on August 01, 2014, 12:20:50 PM
looking awesome alex great work here
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on August 01, 2014, 07:54:18 PM
Thanks steve. 

I was having a little trouble fitting the speaker in the pommel when I finally realized my issue.  I didn't mill out the speaker slot in the pommel spine wide enough.  I left room for the speaker to freely "vibrate" while being secured on the base, but somehow I forgot to compensate for the thickness of the bottom of the pommel.  I can pretty easily widen the slot on sunday when I get home.  It's a 5 minute job on the mill. 

I'm also trying to find the right adhesive for the grips that takes less than several hours to cure.  I basically need to do them one edge at a time, let it cure, and do the other edge.  I tried e6000 but after 45 minutes of holding one edge in place, it still wasn't strong enough to push the other end of the grip down to be glued.  There were a few other types I saw at the hardware store that looked promising.  One said put some glue on each surface to be bonded, wait 5 minutes, then push the surfaces together.  It also said it would be hard to reposition once force is applied, which is exactly what I want. 

The only thing that's killing me is how fragile these little speakers are.  The membranes keep peeling off partially, which ruins the speaker.  It's not like i'm pushing on them or anything either.  Just from a few times sliding in and out of the pommel, they come apart.  Good thing I ordered 6 of them. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Scruffy Nerf Herder on August 02, 2014, 12:20:43 AM
Phew, that thing is a beaut!  I wonder what the next MR conversion is going to be...Vader perhaps?
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on August 02, 2014, 05:13:23 AM
Vader would be far too much work when you can already just go with an mpp replica.  Maybe an episode 3 vader would be worth it but it would be a ton of work either way.  I had thought about an ani aotc since the tridcloud version is so poorly designed imo (the grip slots are absolutely terrible because the aluminum has no strength there) that an MR conversion would be better.  The saber itself is beautiful, but man was it made harder than it needed to be. 

For anyone curious, I will NOT be attempting a sidious. 

I'd like to try a mace episode 3 but they are very hard to come by and very expensive when they do surface. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on August 04, 2014, 09:14:27 AM
Just finishing up attaching the grips and this saber is done.  Might have to make a new brass pommel greeblie if it doesn't polosh properly but meanwhile i'll get some glams and a vid later today or early tomorrow. 

I have some pms to read today too.  Been so engrossed in this build I havent had time. 

Title: Re: MR LE Count Dooku Conversion WIP
Post by: Pinousse on August 04, 2014, 10:10:19 AM
 :D :D :D
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on August 04, 2014, 10:30:53 AM
here are the final WIP pictures of the first hilt.  Last night I spent about 5 hours cradling the pommel so that the speaker would epoxy in the correct place (couldn't put the pommel screw in because the wire for the speaker was in the way initially, and wouldn't move without the speaker moving until the epoxy had cured fully).  The covertec recharge port is perfect, but the powdercoating job is a little lacking.  It's tough to powdercoat something with such a deep recess as this covertec knob had, and I got a little pool of powder in the bottom of the charger hole.  I'm going to see about having a pair of covertec knobs like this anodized instead, but I'm not sure if it's feasible yet. 

Also, I machined a special punch for cutting the wider hole out of the elbow grip for the covertec knob.  Instead of just cutting the hole for the size of the port and letting the covertec rest on top of the grip (like the factory one) I went ahead and extended the covertec through the grip so that I get the extra few threads from the charge port for strength. 

I will tell you guys this, the only thing more boring than watching grass grow is holding a piece in place while epoxy dries.  These grips have taken me since 8:00 this morning and they still aren't done yet.  I still have half of each side grip to go. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140803_172302_zps63n8uo1g.jpg&hash=cd5eb169756050837bd334e7ef9cf28f1346079a) (http://s1099.photobucket.com/user/agordon117/media/20140803_172302_zps63n8uo1g.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140803-WA0006_zps5hciqaot.jpg&hash=57960afcb289a9baacc0a2749cdcb24ea00dbd50) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140803-WA0006_zps5hciqaot.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140803_180327_zpsmiy7we4q.jpg&hash=e03549c0c4575fd88248c74305c098497214825e) (http://s1099.photobucket.com/user/agordon117/media/20140803_180327_zpsmiy7we4q.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140803_235821_zps91cxcsza.jpg&hash=f99459d77b2395c05be76a4e9387ec5eaf4a5ffe) (http://s1099.photobucket.com/user/agordon117/media/20140803_235821_zps91cxcsza.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140803_235827_zpsc73rvywp.jpg&hash=b6b62c948da1f9de002752cc9bd58fc934abce40) (http://s1099.photobucket.com/user/agordon117/media/20140803_235827_zpsc73rvywp.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140804_131356_zpsp0qlpdwa.jpg&hash=26d7d25af595d99a882cf63f6d5f988d312766e2) (http://s1099.photobucket.com/user/agordon117/media/20140804_131356_zpsp0qlpdwa.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140804_131351_zpsiumiartb.jpg&hash=7cf522d31469fa04c817034e4b8b338a8d171da6) (http://s1099.photobucket.com/user/agordon117/media/20140804_131351_zpsiumiartb.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140804_131343_zpsr9f7yu7u.jpg&hash=31ff4d57a8a6d5cd9e2539a71a4d8cb4a58ae9b3) (http://s1099.photobucket.com/user/agordon117/media/20140804_131343_zpsr9f7yu7u.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140804_131321_zpsi9yhfm2d.jpg&hash=c035feaa543882701954a009767772022217ebaa) (http://s1099.photobucket.com/user/agordon117/media/20140804_131321_zpsi9yhfm2d.jpg.html)
main blade

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2F20140804_131326_zpsrfa3tai6.jpg&hash=5dde9da504b674db6385fd9993608e1112102a18) (http://s1099.photobucket.com/user/agordon117/media/20140804_131326_zpsrfa3tai6.jpg.html)
foc

The volume is much louder than I would have anticipated.  It's louder than an awesomesauce or OM obi tpm, but not as loud as an MHS build or something like a MKVI.  It's just right IMO.  Without the pommel insert (for the top of the pommel) it is actually comparable to MHS sound levels, but I wanted the pommel insert there to maintain the totally accurate look of the hilt.  For no visible sound holes this is as loud as they come. 
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Caine on August 04, 2014, 10:35:55 AM
Very, very impressive. You have done an amazing job on this.
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Darkjedi on August 04, 2014, 11:14:01 AM
Whew that as hard as it was beautiful.

Great job. This is a very enlightening thread.

 Is anyone else gonna be this brave to leap for one more of these :o.

If you too want a challenge. I guess the LE's is where to go. C:-)

Flawless
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Pinousse on August 04, 2014, 11:39:47 AM
 :o cant find appropiate words.....
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Justintmars on August 04, 2014, 12:49:22 PM
Amazing....
You are a true prodigy
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Aginor on August 04, 2014, 12:57:49 PM
Great work Alex! It looks awesome!
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on August 04, 2014, 08:39:39 PM
Thanks everyone.  My speaker blew after very little use, so i'll have to open up the pommel to replace it and then go through the process of re-epoxying it in place tomorrow.  I am glad I only used a few dabs of epoxy to hold the pommel insert on now.  These little speakers are crazy fragile.  The membranes peel off if you breathe on them the wrong way. 

I put the almost finished saber back on the stand to see how it looks.  Man does it look good. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG-20140804-WA0016_zpsi0sw8ns3.jpg&hash=edde8b5bd338c64690c5999507a9b790398c06c3) (http://s1099.photobucket.com/user/agordon117/media/IMG-20140804-WA0016_zpsi0sw8ns3.jpg.html)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: ANAKIN SKYWALKER on August 06, 2014, 08:11:05 PM
MVI 0863 - YouTube (http://youtu.be/k4A4DgiLo4k)


Glams to come tomorrow.  Tweaked a couple of things since the video.  Also need to purchase and add lordblako's dooku font to this.  i also realized if/when i pony up for a cf7 for this build, it will be a 20 minute swap.   

You guys can't even imagine how happy I am with how this turned out.  :D
Title: Re: MR LE Count Dooku Conversion WIP
Post by: scottjua on August 06, 2014, 08:30:56 PM
epic epicness is epic. Love it dude... good on you. I definitely have zero desire to tackle that... ahhahaha I did... but not now...
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Pinousse on August 07, 2014, 01:11:39 AM
When talent, art and strong will are put together that gives your asome saber, plus all the details like covertech recharge port and trigger are there, a verry exceptionall saber!

When I will again mill custom parts and soldering little pads or some mad accid etching I will remeber the amazing guys will finely convert a MR LE dooku lightsaber and then bring some of my oldest dream it to light :)

That will help me to shut up and work ;)

Thank to share this amazing work with us all :)
Title: Re: MR LE Count Dooku Conversion WIP
Post by: Greebles on August 07, 2014, 05:46:58 AM
It turned out amazing. Awesome job, looks like the effort really paid off.

-Denzil
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: ANAKIN SKYWALKER on August 07, 2014, 08:38:10 AM
thanks guys.  I just downloaded Lord Blako's Count Dooku font and Darth Xusia's Dooku font (both sound amazing) so I'll be loading those up shortly.

photos are uploading now and should be posted within a few minutes, but just in case, I wanted to go over the tweaks I made yesterday.

I just messed with the sd card really but there was one mechanical improvement I made.  The pommel was held on by a single screw before that was very loosely threaded (from MR) into the pommel coupler.  It served no real purpose other than to hold the pommel loosely to a single point on the coupler.  It still was loose from there, so I knew I needed to make some kind of threaded joint that attached to the pommel itself, so when I screwed in the screw, it actually held the pommel rather than just serving as a loose pin.  I re-tapped the original threads to 6-32 and made a very short threaded brass standoff from a piece of 3/16" tubing.  I screwed that on to a modified 6-32 button head screw, and screwed the whole thing into the pommel.  It fit perfectly into the hole in the pommel, requiring no adhesive (which surprised me) and it is now a rock solid attachment that can't even move by force.

Unfortunately, my speaker is sounding raspy again (not sure what the problem is) so it either needs replaced AGAIN or there is possibly a small piece of swarf floating around in the pommel that I missed when I tapped the coupler for 6-32.  I'm going to open it back up shortly and figure out which it is.  I do have one theory if the speaker is blown again (peeled membrane) but I really hope I am wrong.  My theory is that when I have to hold the speaker in place to epoxy it, just me applying light pressure to the edge of the top of the speaker is too much for the membrane to handle.  Over time, the glue (that holds the membrane on the speaker) weakens, and then it blows.

I'm hoping it's just a small piece of swarf floating around that got caught in the rear of the speaker. 

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0866_zps6f1b19d9.jpg&hash=8e7232b7e579ef3f9415e76d28ca299a75f46323) (http://s1099.photobucket.com/user/agordon117/media/IMG_0866_zps6f1b19d9.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0870_zps908465e8.jpg&hash=653bbda145d59798813dacee9d036fd1b60bcb44) (http://s1099.photobucket.com/user/agordon117/media/IMG_0870_zps908465e8.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0871_zps9e84829a.jpg&hash=4836e51257ac92118b7b0600e693533168f4cc28) (http://s1099.photobucket.com/user/agordon117/media/IMG_0871_zps9e84829a.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0873_zps85e4f575.jpg&hash=23d568650dae5c8582ac7716c144c03b34acdca7) (http://s1099.photobucket.com/user/agordon117/media/IMG_0873_zps85e4f575.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0877_zps5b381a0c.jpg&hash=a0e21eb76404ea68443d5662096a7c229fe401a6) (http://s1099.photobucket.com/user/agordon117/media/IMG_0877_zps5b381a0c.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0878_zps5e250d60.jpg&hash=2a7fc1301bab6b147a1d199e5e4c0275466cdc68) (http://s1099.photobucket.com/user/agordon117/media/IMG_0878_zps5e250d60.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0882_zpsa89d4e4e.jpg&hash=8e94e1f7dbe18e0095c6d97cf2ba50157ad9a7ae) (http://s1099.photobucket.com/user/agordon117/media/IMG_0882_zpsa89d4e4e.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0883_zpsbb7030ef.jpg&hash=3b4209d91508c57c5b67a80725f95353dc16b287) (http://s1099.photobucket.com/user/agordon117/media/IMG_0883_zpsbb7030ef.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0884_zps6e7f52c7.jpg&hash=b57e14e493e23f1f6dc5a92c3ba63643813d0e12) (http://s1099.photobucket.com/user/agordon117/media/IMG_0884_zps6e7f52c7.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0885_zps7a0368d2.jpg&hash=368f788f513d63cfe83540d2060a099e4905f95b) (http://s1099.photobucket.com/user/agordon117/media/IMG_0885_zps7a0368d2.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0886_zpse193d558.jpg&hash=edb316067352134d68b9a273a4ed9d901acc1d7e) (http://s1099.photobucket.com/user/agordon117/media/IMG_0886_zpse193d558.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0888_zps2b253ac6.jpg&hash=49cc25e938c912024cbcfaa75dd8d261724568f3) (http://s1099.photobucket.com/user/agordon117/media/IMG_0888_zps2b253ac6.jpg.html)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fi1099.photobucket.com%2Falbums%2Fg384%2Fagordon117%2FIMG_0889_zps7c881c37.jpg&hash=31f48db443c5f43edf378c0080d67ee2e1165288) (http://s1099.photobucket.com/user/agordon117/media/IMG_0889_zps7c881c37.jpg.html)


Title: Re: MR LE Count Dooku Conversion *finished*
Post by: Clark Kent on August 07, 2014, 08:41:20 AM
very nice man, very very nice.

i like how you actually made the trigger work. no one has done that before. i love it.

like you said, your Mona Lisa, congrats bud. you did it.
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: Pinousse on August 07, 2014, 08:51:53 AM
The last picture is stunning it feel like it was a real lightsaber ;) Again amazing work!
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: ANAKIN SKYWALKER on August 07, 2014, 08:56:50 AM
The last picture is stunning it feel like it was a real lightsaber ;) Again amazing work!

I really liked how that one turned out too.  I wanted to take more like that but I can't really move the saber around while it's in the light tent with the blade in, and I only have the one 3/4" blade (if I had some blade stock I could have made a short one just for the pictures). 

I also really need a low end dslr to start taking some real pictures of these sabers, but I just keep putting it off.  One of these days I'll grab one. 
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: Malaki-Skywalker on August 07, 2014, 09:10:49 AM
Very inspirational work!  8)

Is this a keeper?

Malaki
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: ANAKIN SKYWALKER on August 07, 2014, 09:21:09 AM
Very inspirational work!  8)

Is this a keeper?

Malaki

Thanks, and yep, definitely a keeper. 

Title: Re: MR LE Count Dooku Conversion *finished*
Post by: Pinousse on August 07, 2014, 10:01:04 AM
Just an humble homage to your amazing work ;)

(https://www.fx-sabers.com/forum/proxy.php?request=http%3A%2F%2Fimg11.hostingpics.net%2Fpics%2F867407Dookulightsaber.jpg&hash=d9badfd5767f2ef9288ab818c65898d6322c978d) (http://www.hostingpics.net/viewer.php?id=867407Dookulightsaber.jpg)
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: CHEWBACCA on August 07, 2014, 10:29:39 AM
Great job Alex!
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: ANAKIN SKYWALKER on August 07, 2014, 10:32:03 AM
Thanks for that!  Looks great!

Opened the pommel and the membrane was indeed peeled back from the speaker again.  Instead of replacing the speaker this time, I tried gluing the membrane back down.  It actually worked perfectly, so now i'm re-closing up the pommel.  Hopefully, it just works this time.  We'll see soon.  Again, the speaker has plenty of room so there is nothing causing this once it os closed up. 
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: CHEWBACCA on August 07, 2014, 10:58:50 AM
Thanks for that!  Looks great!

Opened the pommel and the membrane was indeed peeled back from the speaker again.  Instead of replacing the speaker this time, I tried gluing the membrane back down.  It actually worked perfectly, so now i'm re-closing up the pommel.  Hopefully, it just works this time.  We'll see soon.  Again, the speaker has plenty of room so there is nothing causing this once it os closed up. 

I have had that happen with several of the small speakers and have glued them like you mention. 
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: ANAKIN SKYWALKER on August 07, 2014, 11:01:45 AM
It's back together again and sounds perfect.  Hopefully the glue holds.  Now to glue the other 8 back together.   ;)
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: Scorpion on August 07, 2014, 11:06:42 AM
awesome alex well done mate, im glad as well as you are no doubt that it is finally complete,
so now you know how to do these is it something that you may offer as a service?

and whats next?
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: ANAKIN SKYWALKER on August 07, 2014, 11:14:36 AM
awesome alex well done mate, im glad as well as you are no doubt that it is finally complete,
so now you know how to do these is it something that you may offer as a service?

and whats next?

I'm not sure I would be comfortable charging the kind of money it would take to offer these as a service.  It would take forever to do one too.  Weeks and weeks once I started.  Definitely wouldn't be a "regular" service either. 

No clue what's next.  Thought of a mace, but they are really hard to come by and a few other things make it not worth it to do.  An accurate sidious is not mechanically possible, and the rest have either already been done as runs or have already been converted (so has the mace to be fair). 

I do have an orgus din on the bench though but i'm unsure if i'll convert it or doit from scratch. 
Title: Re: MR LE Count Dooku Conversion *finished*
Post by: GusManB on August 07, 2014, 06:43:31 PM
Congrats! on A job well done.
That hilt looks like it is Small with vary limited space, Wow