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Hello Cosplayers, Makers, Star Wars fans. See how Thomas makes a cool Lightsaber with common hardware and flashlight parts, along with Polly Plastics Moldable Plastic.

Step 1: Watch the Video

Step 2: Gather Your Tools and Materials

  • Polly Plastics moldable plastic
  • 12 inch PVC drain extender
  • Sink drain replacement kit
  • Random parts (Thomas uses flashlight pieces, Super Soaker parts and metal washers in this build)
  • Rust-Oleum Hammered Enamel Paint
  • Rub ‘n Buff Wax Metallic Finish – silver and gold
  • Super Glue/ contact cement
  • Dremel tool
  • Hot glue gun with glue sticks
  • Cutting tools
  • Leather (optional)

Step 3: Assemble Your Parts

  • Draw a line on the PVC drain extender about 5” from the smooth end of the tube.
  • Use the Dremel to cut off the 5” piece.
  • Cut a rectangular slot through PVC part from the drain replacement kit.
  • Find your random parts that you can fit onto the PVC pipe. Here Thomas uses Super Soaker parts and flashlight parts. Attach with hot glue.
  • Heat ½ cup Polly Plastics moldable plastic, following the usage instructions, and use the molten Polly Plastic to secure your random parts to the PVC pipe and fill in any gaps.
  • Continue adding the rest of your random parts. Add enough moldable plastic to smooth and bevel all edges.
  • Insert the metal sink drain part into the end of the PVC slotted part.
  • Use Super Glue to glue any random metal parts onto other metal parts.

Step 4: Paint/Rub ‘n Buff

  • Use Rust-Oleum Hammered Enamel for the base coat for your lightsaber. Do not paint the metal sink drain part that fits into the PVC pipe.
  • Brush Rub ‘n Buff over the surface of the painted parts. Add a bit of water to the paste to make it easier to apply. Apply silver and gold to the get the look you want.

Step 5: Final Touches

  • Cut a piece of leather and attach it onto the lightsaber handle with contact cement.
  • Re-install the metal sink drain part unto the end of the lightsaber.

Step 6: Congrats!

Here is a picture of your finished Lightsaber.

Hope you had fun. Subscribe to us on Instructables and YouTube. Look for more Instructables in the future and be sure to check out all our craft and moldable supplies.

<p>That looks really nice. The next time that my son asks me for a toy light saber, I am just going to show him how to make his own. </p>

About This Instructable

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Bio: We specialize in plastic molding materials and plastic pellets for hobbyists, crafters, players, fixer-uppers, makers or anyone who wants to try stuff.
More by pollyplastics:How to Work With Moldable Plastic How to Make a Lightsaber With Polly Plastics 
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