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Author Topic: Shadow Guard pike with CFv6  (Read 3017 times)

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Offline erv

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Shadow Guard pike with CFv6
« on: July 10, 2014, 01:36:56 AM »
I haven't posted any of my builds / installs for a while. That one is old too, but I thought I'd share as a customer recently asked about a pike install.
It was formally done with a CFv6 but I recently upgraded it with a CFv7.
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I met Jonatan at FACTS12, we started talking about having his pike equipped with electronics. I don't have much time along the year for my own installs but I though it would be nice to help a fellow RL / 501 member.

His pike is a nice item (can't recall from who he got that, RPF or else), good machining, all powder coated, and electronics ready. Comes in 3 or 4 pieces that screw all together.



He wants a full power setup, no white FoC, basically the goal is a bright blade for posing with visitors during conventions, not much interaction or  duel or jedi-iscisms. Flicker though, will definitely add up and even if sound will always remain shy in a public space, he will enjoy that at home

There's not much room but fortunately, the designer has thought about a switch location and battery pack in the lower part, just below the emitter section. I initially thought about 18650 which were fitting but with no room for any wires and I'm definitely not equipped to bore a tube of 30cm long.

So I chose some non protected 16650, 2 cell pack, with 2 cell PCB added separately. LEDengin RRRR seriallel, no FoC, to have the max brightness all the time.
The first step was to machine a nice and sturdy chassis. As the tube ID is like 18 something, such a small wall to bore is always difficult in plastic (at least for noobs like me and without creating a custom collet for it) so I adapted a few bits of 3/4" blades for the ends of the batt pack. The blade segment connects then to a chassis milled in a PVC rod, with wire channels and shouldered section to welcome the switches and the protection circuit board of the batt. pack.

still very WIP, here are some pics












Offline erv

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Re: Shadow Guard pike with CFv6
« Reply #1 on: July 10, 2014, 01:37:44 AM »
Got the body drilled for the switches plungers. Stressing moment of proper clamping and centering, didn't chip off the PC job  8)



Then final install of the chassis. Single hidden screw to secure it in place, it's already very snug inside, tight machining tolerance made so that polyC rings expanded juuust a bit to push a little once the cells are inserted.

Knurled Jango killkey = perfect job for this project




Offline erv

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Re: Shadow Guard pike with CFv6
« Reply #2 on: July 10, 2014, 01:40:04 AM »
finished the install

Ledengin wiring.





Machined chassis, I milled extra room in the front to have the LED connector fitting.




tight fit with the front screw, used as a blade holder holder (it's like the green lantern lantern).


Result. I have to say that it's the first time I'm really impressed by a ledengin. Probably because my latest attempt had a 3/4 blade and limited current. 4 dice running at 1A = win. Newer leds probably beat that but 1.5 year ago, that was pretty bright !


Offline erv

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Re: Shadow Guard pike with CFv6
« Reply #3 on: July 10, 2014, 01:40:38 AM »
customer returned to me, he's very happy and got his costume (and pike) approved by the 501.

gallery - blade wasn't photoshopped

http://plus.google.com/photos/106379627929213928636/albums/5867168248987360817?banner=pwa





Offline Wildcard

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Re: Shadow Guard pike with CFv6
« Reply #4 on: July 10, 2014, 08:42:46 AM »
That looks awesome Erv! And thank you for the great, detailed build log!

Offline Greebles

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Re: Shadow Guard pike with CFv6
« Reply #5 on: July 10, 2014, 09:45:02 AM »
Nicely done.

I haven't seen very many of those done. Neat.

-Denzil

Offline erv

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Re: Shadow Guard pike with CFv6
« Reply #6 on: July 11, 2014, 04:32:19 AM »
thanks guys. Nothing "complex" per say, just an unusual type of install and split of the electronics / batteries. Essentially custom machining, I totally enjoyed it.

Offline Wyrlock

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Re: Shadow Guard pike with CFv6
« Reply #7 on: July 11, 2014, 06:43:43 AM »
Nice! I was thinking about building one as a project after playing TFU the other day...
I want to go home and re-think my life...

Offline Professor Huyang

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Re: Shadow Guard pike with CFv6
« Reply #8 on: July 11, 2014, 06:46:28 AM »
Sweet. I love a saber pike. Thanks for sharing erv.
"Many years I have been on this ship teaching many a Jedi before you, and I will continue teaching many a Jedi after you. Call me what you want, but inside my memory banks I contain a record of every lightsaber ever made, and the Jedi who fashioned it."
―Huyang


Offline CHEWBACCA

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Re: Shadow Guard pike with CFv6
« Reply #9 on: July 11, 2014, 07:02:36 AM »
That turned out great erv, nice thought out design and very neat and tidy!


Offline Justintmars

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Re: Shadow Guard pike with CFv6
« Reply #10 on: July 11, 2014, 07:57:10 AM »
Amazing....

thanks for sharing.

Perfect item to top off a wicked cool costume!

Offline Cad-Bayne

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Re: Shadow Guard pike with CFv6
« Reply #11 on: July 11, 2014, 08:12:56 AM »
Me likey!!!



Offline Iamhomostellaris

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Re: Shadow Guard pike with CFv6
« Reply #12 on: July 11, 2014, 08:56:37 AM »
"Nothing complex"!!!!
Yeah CF7 is not complex at all  :))
Without joke this is a fresh and nice prop you achieved here, thanks for the share Erv!!
We are all looking at the stars, we are Homo-sapiens-Stellaris.
when I see other's sabers I might think they have build them like a Tardis, bigger inside than oustide. Unlike mines huhu.