UPDATE: I've been super busy taking part in Dallas Red Bull Flugtag. I am part of Team Dworks.
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.
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
I used to own a 7x12 metal lathe.
I sold the lathe