So it's all done, here's whats in it:
All MHS parts (with some custom work)
Flush mount activation switch
AV aux switch
2 accent LED's
Regal standard speaker
Inline rubber grips
Standard recharge port
and lots of wires :)
And here's some pics:
CF5.06 (yes, the power extender wasn't finished in this pic)
There wasn't room for a chassis in this hilt, given that it's so short and the inline rubber grips already reduced the ID quite a bit, but I got it all to fit by stacking a twin pack 18650 under the CF. It's nice and snug, and further secured with a bit of epoxy putty.
Super easy SD card access (rear of hilt).
Pic of lower box installed with recharge port and LED.
The rest of the wiring was done by screwing on the top black piece and threading the wires through the holes cut for the #9 Box. Then, the main LED was soldered to the led driver and FOC wires, secured in place, and emitter screwed into the hilt. Lastly, the LED and AV switch were installed into the #9 box, then wired to the saber and screwed into place. Then BLAM! All done :D
Normal blade color:
The FOC is much more defined in person, as it shimmers and flickers rapidly. Will be more noticeable in the video.
You'll notice in this picture that there are two retention screws going through the mid section of the saber:
Your eyes do not deceive you, as they are going straight through the threads of the MHS parts. That section of the saber never needs to be taken apart, and really can't be, cause the switches and recharge port wires can't twist. This way, I'm not worried about it ever twisting while I'm using it, and it generally gives the saber a more secure feeling. Only the pommel and emitter can be unscrewed now.
The blade main color is more purple then in the pictures, though it is not a true purple. It's like a darkish magenta in person, which isn't what I wanted, but it will do. The hilt is quite small and light, and I even fit two 18650's in it, so it has excellent run time. I will have a video up of it in a few days, still playing with software. Hope you guys like it :)