Jedi Lightsaber Custom Build (Custom Gladius with reveal core)

[Darth Ryô]

Jedi Lightsaber Custom Build
with Plecter Labs' Nano Biscotte
(from a SaberForge’s Gladius stunt)




Hey all!

My Sith Custom Build now has its counterpart / enemy ^^
This one has been built almost at the same time so you’ll see many familiarities, but it is still a bit different (obviously).

From the outside, it’s again pretty much what the SF hilt looks like; except for the crystal chamber windows that I added. And again, I wanted to do a nice reveal core (as well as an easy way to access the battery and the SD card), and design a 3D printed chassis specifically for it. This time, I also painted that 3D printed white plastic in order to make it fit better with the rest of the hilt, as well as to give the crystal chamber some accents.
I let you judge how this one turned out, on my side, I’m pretty happy with it ^^



Here is a link for the video:
G.O.T.H. Custom Sabers - Custom Jedi Saber - YouTube

Specs:
- Saberforge Gladius stunt hilt, with a few mods… most of all a cut in half saber, a Crystal Chamber windows and an additional polish.
- Custom core tube by Oxalainen, with additional mods for the reveal on my side
- Completely custom 3D printed chassis (Shapeways material - White Strong & Flexible plastics, painted)
- Green led module (2 Cree XB-d)
- Nano Biscotte V1 from Plecter Labs
- Single removable 18650 Cell
- Railmaster bass speaker
- 1” thick walled transwhite blade


Photos:
















Build log photos / detailed description:

Original hilt… which I cut in half


Core tube made made by Oxalainen, and then cut by Dremel



Was it stressful to slice that hilt in half? Naaah, let’s torture it a bit more then ^^
Oh yeah that was fun!


That took quite a long time again, but was well worth it!



Time to put back the leather wrap


And then I cut an aluminium mesh to the size of the crystal chamber windows, and it gets locked between the hilt and the core tube (press fit kinda). The core tube is then permanently locked into upper hilt, press fit helped with strong epoxy… that thing ain’t going anywhere ^^




Now the 3D printed chassis I designed for this build.
It is meant to hold a NB, a 18650 battery holder (bought at TCSS), a Railmaster Speaker, 2 switches, and a crystal chamber… sort of all in one to make the install as easy as possible… I made a mistake with the first chassis I designed, but once corrected, it worked perfectly.


And the install finally begins



You’ll again notice 2 switches here:
- one serve a kill key (there is no recharge port, since this saber uses removable 18650 cells like this Trusfire I used for my tests). And after all the NB doesn’t need it thanks to its sleep mode ^^
- the other switch serves to shut down the speaker… stunt or display mode sort of, like @vektor do on his builds ^^

Once the install done, everything can go back in the core tube, and fits just perfectly… that’s the beauty of 3D printing, as precise as it gets :D



First and final tests, we have a GO ^^

[Greebles]

Nicely done!

-Denzil

[EXAR KUN]

Very cool. Looks like it is a LOUD saber,... looks like there is good resonance.

[wolf10100]

and he is at it again chopping those sabers in half lol

looks good my friend. Never thought about painting the chassis before. Did you find that you managed to remove some of the textured feel of the chassis by painting it or does it keep that usual printed feel (you know what I mean lol)

[Wildcard]

I'm really liking the core and chassis combinations that you've been doing; great work!

[Starwinder]

Gah!  So much awesome!  The core/chassis is really really cool.  Keep up the good work!

[Iamhomostellaris]

Wow very nice work thanks for sharing!

[Darth Ryô]

Thanks very much guys ^^ I had a lot of fun making these!

@SpaceWindu: Yes it is pretty loud (good thing the nano has a volume parameter).
Actually, the speaker is as close as it could get to the pommel (which length have been quite reduced too). But thanks to the pommel structure, there is indeed a very good resonance still.
I guess that will show in the upcoming video ^^

@Wolf10100: yeah mate, I know what you mean ;)
Before painting it, I washed / cleaned / brushed the model (like we usually do with resin figs), so that helped a bit removing the first dusty feel.
But then, I could say the paint made it very slightly smoother, but I think the overall feel remains the same.
Like I say elsewhere, gotta try painting white polished models, these had a much better feel.
But in this particular chassis case, I'm good with unpolished, as I like very much how the paint turned out with that rather rough surface :)

[Ho-Wai Lowill]

i seriously think you have some nice designs Darth Ryo, especially with those custom chassis, this turns out great.

[CHEWBACCA]

That looks great.  I love the chassis and the AL surround...great work.

[Noir1990]

Great build with so many details. I love the emitter and the leather on the grip. Such a beauty =)

[Darth Ryô]

Thanks again ;)

Short demo video is now added:
G.O.T.H. Custom Sabers - Custom Jedi Saber - Vidéo Dailymotion

[EXAR KUN]

Video is great.

That saber is really awesome. Love the insides of the saber as well as the outside.