Build a Lightsaber

So you have decided to take the final step to embracing the force. Does your path follow the Light or the Dark side? (I hear the dark side has cookies).

What ever side you are on, what follows is how to make a Duel-Worthy Lightsabre. That means, you should be able to wield this sword and bash it against things and other lightsabers with little fear of actually breaking the lightsaber. You may end up breaking other things, but the lightsaber will remain intact.*

Total cost of this project is $60 to $1,000 USD. The wide range in cost all depends of how crazy you get with your design. The cost of lightsaber I built for this instructable is about $160.

The Video: 



NOTE 1: This Instructable is very TEXT intensive.

NOTE 2: Most of the parts used in this tutorial came from The Custom Saber Shop (TCSS). I am not affiliated or employed with them. I am just a customer.

* The author of this instructable is not responsible for property damage, personal injury, amputation of limbs, decapitation, and/or death resulting from the building and use of the lightsaber prop. All legal responsibility or resulting civil action due to said property damage, personal injury, amputation of limbs, decapitation, and or death belongs solely to the builder. The author is also not responsible for anyone falling into the Dark Side. The author will also not be held responsible if an agent of the Dark side decides to fry you with lightning coming out of his/her fingertips*

Step 1 Gallery - My Past Creations

These were my past creations and experiments.
I used to own a 7x12 metal lathe. 
I sold the lathe

Comments

[87Jarod]

Can you tell me how to get ahold of those parts for yours ( the brighest/ KOOLEST one) and it cost about 160??? How much would it cost me to buy that one from you cuase I want one of those soon for halloween please reply soon :D ty :D

[MrTinkerer]

there was a lot of time spent on ebay for the right deal. The hardest part it the sound. happened upon a used MR FX saber for $30. The next hardest is the LED. Can't get it anymore. Best solution is 3 white rebels at about 600 lumens. Then use a colored filter. White LED is about $18. I dont really want to part with my lightsaber, Sorry.

[87Jarod]

ty any ways :)

[MrTinkerer]

If sound is not the main focus and brightness is, here is what u do: Get a brass sink tube at hardware store ($9), Sink tube adapter at TCSS and blade holder ($6 and $25), 3-up Rebel star white and optics from luxeonstar ($30 for 600 lumen), blade from ultrasaber ($19, thanks memoriable), sound board from cheap hasbro toy ($20), battery pack and buck puck ($30).

Total $139.

Use color filters to change the white to what ever color you want. my super bright pure green  lightsaber is pumping out around 360 lumens, the white star can put out 600 lumen.

[tinker234]

hey could i make a working one using plasma in the handle that came out of liltle holes in the blade that retracts so a real dnagreas lightsaber i love the waring

[memoriable]

Hey tinker234,
MrTinkerer is right on, we currently don't have a reasonable way to build a lightsaber.
If you'd like, you can check out an article I wrote all about it here: Real Lightsabers

[tinker234]

using high tech ceramics you can have the clash

[tinker234]

thanks you know a magnetic field can hold a stable plasma maybe the light club perhaps it is possable

[MrTinkerer]

no

[tinker234]

why not

[MrTinkerer]

Because there is currently no plasma generating and containment technology that is small enough to fit in a hilt. Also, plasma has a very localized effective area, the longest plasma "cone" is less than 10 inches long and the machine that makes it is probably the size of fridge. Plasma also requires a constant stream of high pressure gas. When the gas is used up, the plasma stops.

Wiki... http://en.wikipedia.org/wiki/Plasma_cutting

[acoleman3]

michio kaku has figured out how to make one.

http://science.discovery.com/videos/sci-fi-science-designing-a-light-sabre.html

[tinker234]

well magints acn manuplat plasma and any way rhe batterys wois the only thing that needs work

[memoriable]

Ultrasabers Has A Whole Section Dedicated To Getting You The Parts You Need For Building Your Custom Lightsabers. Visit It Here.

    -Custom Lightsabers

[memoriable]

The Most Commonly Used Battery To Build Custom Lightsabers With Can Be Found: Here (Also Comes With A Charger To Make Things Easier) 

   -Custom Lightsabers

[StArwArsN3rd]

Is there any way to make the hilt from scratch from buying the parts from a hardware store or is that the point of the last "Or" section in this step? i like to no so i dont go buy expensive parts that i could possibly find for cheaper else were.

[memoriable]

For All The People That Dont Have The Equipment Or Know-How To Fashion A Fancy Hilt. You May Be Interested To Know Of The Premade Hilts Made By Ultrasabers Which Are Stylish, Easily Assembled, And Can Also Be Added On To For More Originality. 

     -Custom Lightsabers

[MrTinkerer]

Yes, you can just buy a chrome sink tube and an assortment of PVC couplers, joints and pipes. We some creative engineering you can shape the PVC to hold the blade securely on the chrome sink tube.

[memoriable]

IMHO, The Corbin Blades Dont Light As Even As iWould Like. The Only Blades That Have Ever Done It For Me Are The Ultrasaber's UltraEdge Blades. I Just Like The White Core Effect With These Blades. And If You Look At The Movies, Youll Find That The White Core Is Actually There With Every Lightsaber So iFind Its More Realistic Also.

  Hope I've Been Some Help,
              -Custom Lightsabers

[DELETED_kage_no_akiri]

(removed by author or community request)

[memoriable]

Here is the link for the Ultrasabers soundboard: Obsidian USB Soundboard

[acoleman3]

oh bang on! thanks a lot.....

kenkou ooku no seimi
good health and long life

[Rikudara]

im sorry for the trouble but could you please explain what you did with the end cap and the reflective disk ? did you use the round cut out of the adhesive foil , fix it to the end cap and then stick that part to the pc tube ??

[brainiac120]

Just added it up. gunna buy one from ultrasabers instead since it's in my budget.

[MrTinkerer]

Cool. What you gonna buy? I have been considering buying one of their pre-assembled blades.

[brainiac120]

One Question: can you make this on a budget of $60?

[MrTinkerer]

it will be a little over 60. Hardware parts only, maxed out at 180 lumen, no sound. The most expensive part would be the polycarbonate blade.
Parts list for a ~ $60-$75:
Chrome sink tube $7-$9
1 LED Luxeon or Cree $6-$9
LED lense - $4
assorted PVC couplers and fittings (to hold the blade)$4
push button switch $2
polycarbonate blade $15
diffussion film $6
blade tip $4
battery holder $1
assorted screws $5
I'm sure I forgot something...
Good luck

[brainiac120]

Thanks for the help!

[thats mr sonic to you]

that is so cool thanks wiz kid in a nice way

[lord vader]

how do i get lightsaber sounds onto a sound board because i found one in my toy car {3

[MrTinkerer]

dont know

[fight4gipper1]

The end cap you used looked very alien compared to the blade tubing. Have you found an alternative since???

[MrTinkerer]

nope

[whisper199]

id totally be on the DARKSIDE (dont forget the cookies) NOT!!!

[xXRRAAWWRRXx]

i'm totally gonna do this for a no more heroes prop :3

[pman123]

Hey I was wondering about something...if I buy a pre-made and working lightsaber from ultrasabers.com, can I install sound? if so, where would I buy the supplies and how would I do it?
I would buy a lightsaber with sound from them but they are about $400...

[dcatalystmx]

I have been looking into building my own lightsaber for some time now, and so far this looks very helpful, I have one question though, where did you purchase the LEDs? I can't seem to find them except in bulk from future lighting solutions.

[MrTinkerer]

small quatity orders are possible from MANY internet sources. thecustomsabershop.com, DealExtreme.com, luxeonstar.com, ledsupply.com. Google is your friend.

[Sergnation]

So are these clash able, like some ones you can buy in store. just these are so bright.

[MrTinkerer]

Yes, my lightsaber makes a clash and woosh sound when swinging and hitting, just like the $120 lightsabers in the store. Difference is that my blade will not break or crack from a heavy impact.