So I've posted questions in a few places about this build, but I didn't want to make a WIP thread till I had a good amount of work done, and something worth showing. Now, I think I do. This started out as an ultra-sabers Phantom V3, then got the guts pulled out, and some of the anodizing sanded off.
How it looked when I bought it:
First sanding job (done using a belt sander and then hand sanding with a fine grit):
I wanted a star-killer esq crystal chamber in each side of the staff, which I just got the slots milled out for this week. I originally was going to cut away about 1/3 of the staff for the chamber reveal, but ended up going with a much thinner slot for structural and comfort reasons. I then sanded down the emitter sections quite a bit using a high grit sand paper (and about two hours on a belt sander) so that MHS
sleeve material would slide over it. I also threw a bevel into the end of the emitter, cause I think it will look great with the overlay, which is designed as a clover with deep slots, so the rings in the emitter will be able to be seen through it.
Crystal chamber slots
I also added 5 holes to the top of the staff for a spaced out bar graph. When assembled, the holes face upwards, with the crystal chambers facing opposite directions at 90* of the holes.
This is the crystal chamber I originally designed for this project, but won't be able to use, as I decided to make the slot smaller, and the details in it would be lost.
So I settled by making this
Very simple crystal chamber. I shaped the crystal from 3/4" acrylic rod using.... you guessed it, a belt sander! (Can you tell I like that tool?) The brass pieces are 1/2 and 17/32's tube nested together for more depth and detail. The crystal also has a deep hole drilled in it's center were a wide angle blue LED sits. Though it is quite simple, I think it fits the slot very nicely.
And it also looks right when looking through the slot at an angle. I made sure to make the brass long enough to have depth and not be able to see the chassis when looking in the slot sideways.
And it will be powered by none other then a CF5 (my first CF
This is going to be a permanent staff (as in won't separate into two individual sabers), so I have lots of room inside to play with. It's going to have an anti-vandal switch mounted on an MHS piece that will thread into the middle of the staff, which is preventing my from using an 18650
pack, but I can still mount two individually on either side of the switch and then solder them into the board in series. The sound is going to vent through the crystal chamber slots (which I already tested and works great). There will be a total of 10 LEDs, 2 main P4
blues, 5 3mm blues for the bargraph, 2 wide angle 5mm blues in the crystal chambers, and the anti-vandal blue ring right in the middle, so it's going to be drawing alot of power. I'm also using two speakers (one before each crystal chamber).
I should be getting the shrouds by Friday (have a friend machining them for me cause it's a bit above me and I don't own a milling machine), so I'll have an update sometime this weekend with those on. I also need to get the black sections repainted, cause I need to sand them down cause the slots are just a tad sharp at the moment. Anyone know where I could send them for powder coating? The inside portion of the staff will be wrapped probably with nylon, for better grip and aesthetics.
Link to bigger pictures:http://s271.photobucket.com/albums/jj129/icetyrant22/#!cpZZ1QQtppZZ20
Thanks for reading/viewing. Thoughts?