You need PARTS.
Go to your local hardware store and buy parts (some parts will not be available at your local hardware store and must be special ordered). If you have a local Surplus Electronics Recycling store near you (Weirdstuff, Electronics Goldmine), go there and rummage around at the old electronics. Gather anything that looks "cool", geeky, futuristic, funky, hi-tech, or would seem useful later on.
Go to The Custom Saber Shop to buy specialty parts: http://www.thecustomsabershop.com/
OR Ultrasabers http://www.ultrasabers.com/
Also go to http://www.onlinemetals.com/ http://tapplastics.com/ http://www.mcmaster.com/
If the parts do not make sense now, don't worry, I will explain each section of the lightsaber in detail in the steps to follow. The Blade:
1 x 30-36 inch long Polycarbonate (pc) tube, thick wall 1 inch outside diameter (OD). Wall thickness should be 1/8 inch. This is the blade.
1 x end cap for the pc tube (blade tip)
1 x blade film ("corbin" film is great)
1 x reflective material with a diameter smaller than the inner diameter of the PC tube. The Hilt:
1 x blade/LED holder (aka the emitter)
1 x 1.5 inch chrome sink tube. 12 inch long
1 or 2 x sink tube adapter. 1 to attach the blade holder to sink tube and 2 if you have opted for a machined pommel.
1 x switch or button
1 x pomel or end cap
What ever else parts you want to attach to the hilt body - grooved section, plates, gold trim, jewels, tapered section, leather. BE IMAGINATIVE. MAKE IT DISTINCTIVELY YOUR OWN. The Electronic Guts:
1 x High power LED (luxeon III, K2, V, Rebel; seoul P4, or any LED with a lumen
output above 60
). Decide if you want to buy an LED emitting a certain color or a white LED and use color filters. The lightsaber I built for this instructable in theory should be pumping out over 300 lumen... In theory. You will see later how I accomplished this.
1 x compatible optical lense to focus the LED to 10 degrees or less.
1 x method to control the current going into the LED - for the example a BuckPuck
was used. A Resistor can be used but that method is less efficient. Sound:
Optional, but without it you just have a stick that lights up. At the very least consider pulling the board out of a Hasbro toy.
battery holder, speakers, sound board, lots of screws, vibration motor, crystal chamber, and wires.
Solder iron 45 watt or higher and some good quality solder.
Rotary tool (Dremel) with sanding drum, cut-off wheels, grinding and shaping tools.
Drill and drill bits
a screw tap set
Glue for metal or epoxy
Sand paper, course and fine assortment