Wrapped this up a couple of days ago, but waited until tonight to get some decent pictures and a video. Check this out:
The saber is based around a 12" long, 1.25" 20 gauge sinktube. The rest of the layers are aluminum tubing of differing diameters. The design is similar to the one I made for my nephew for his groomsman's gift, but is refined and looks a lot better.
Oh yes! It is heavily weathered. I used destructive and non-destructive methods on this thing. I tried to make the weathering as realistic as I could, imagining this thing has had a hard life and seen a lot of time in combat. What's really odd is that you need to make everything PERFECT and pristine before you can properly beat it to snot. Yes, I spent hour after hour smoothing each of my cuts with my needle files...before slamming parts on the ground, nicking them with tools, engraving them, etc. Kind of like undoing a lot of hard work. I like the end result though.
Sound comes from a MR Sith soundboard. LED is a Lux III R/O. It has a 4AAA battery holder that is easily accessed through the pommel to change batteries.
I really dig this saber. It's fun to look at, nice to hold, and sounds really nice. What you think?
Hey, check out the YouTube video too (PG-13 language):
http://www.youtube.com/watch?v=GRb-NIsiJVo