Introduction: Lightsaber Hilt Prop

Picture of Lightsaber Hilt Prop

This Instructable shows how to make a prop lightsaber hilt only. It can be used for display or for carrying on your belt. I haven't progressed to the point of making a "working" lightsaber yet (i.e. lights, sound, blade, etc). This style of lightsaber construction is typically referred to as a "sink tube lightsaber" and is not really the most professional looking version, but if you want a fairly cheap way to have a fun prop than this is an excellent way to go. There are plenty of instructions for variations of this build style already on the internet (and on instructables for that matter) but I was pretty happy with mine and thought I would share.

Step 1: Design

Picture of Design

I went with a fairly basic design. Based on what you want you may have to comb the hardware store aisles looking for something you can use to turn your vision into a reality. All I really wanted was a slimmer handle area with a thicker pommel and blade emitter area. I also wanted some sort of design on the handle to make it less plain, some sort of shape for the blade emitter, and various buttons to make it look like it really did something.

I went through a lot of various ideas before I found one to settle on.

Step 2: Tools and Supplies

Picture of Tools and Supplies

I used:

  • Chrome sink pipes
  • Poly Washers
  • Rubber O-rings
    A Brass Adaptor
    A Chrome pipe cap
    A Cell phone clip
    Bits and Bobs for Buttons
    Dremel w/various attachments
    Super professional safety equipment (okay so I used a bandana and a pair of sunglasses)

Step 3: Cutting Your Pipe

Picture of Cutting Your Pipe

I got two different pieces of chrome pipe; one of them with a wider diameter than the other. I designed a pattern on paper using "MATHS" cut it out and taped it around the pipes. The skinnier piece got some long oval-ish shapes cut out of it. These run horizontally along the handle. I cut a small plain cylinder for the butt of the lightsaber and did another small cylinder, this one with a curved top, for the "blade shroud". I used a cutting wheel on my dremel and then cleaned it up with a cylindrical grinding bit.

The chrome pipe is actually brass (I think? The color is right at least) so when you cut it the brass color shines through. Rather than freak out about this or try to cover it up I sanded around each cut so that it shone through uniformly and looked kind of like a border.

Step 4: Attaching Accesories/Filling It With Greeblies

Picture of Attaching Accesories/Filling It With Greeblies

To connect the two wider diameter pipes to the skinnier one I used these plastic gasket pieces called "poly washers" that I found in the plumbing section of Home Depot. They were almost the perfect thickness so I sanded then down just a hair, placed them on the skinnier pipe and then shimmied (that's the technical term) the wider pipes into place over them. With a little bit of black paint the same poly washers were used to cover up the gaps left around the edges of those wider pieces. The butt end was closed up using some sort of faucet repair stopper I found. I drilled a couple of holes for some "buttons" and "switches". One was made of an LED and a little black rubber mounting ...thingie... another was a little metal peg from Tandy Leather. I also lucked out and found a cell phone belt clip at the dollar store and was able to attach the cell phone side of the clip with a screw. The other side just clips onto your belt and it slides into it.

The holes I cut into the handle needed something to back fill them so I used black rubber o-rings. The initial plan was to put them around a PVC pipe to keep them together but the pipe was too big so I just shoved them all down into the pipe and that worked just fine. You could also use one of those plastic cord hider tubes if you don't want to go with O-rings.

The blade emitter needed to have something that looked like it would actually emit something so I used something called a "male solder adaptor". I put some o-rings around it so it would fit correctly (since the pipe had a wider diameter) and pushed it into the top opening.

Everything can be secured in place with glue, though I will admit that I didn't because I want to be able to convert this into a "functional" lightsaber in the future. Even without gluing everything together it fits together tight enough that it holds together well enough to carry around and handle, though I would glue it together before doing anything too rambunctious with it for fear that a piece of it would go flying.

Step 5: Wearing It Like You're Too Cool for School

Picture of Wearing It Like You're Too Cool for School

Now that it's all together you can slide in it into it's place on your belt and walk around like you own the galaxy. Or pair it with a costume and mind trick people into giving you candy. Or wear it to the premier of the new movie! Or anything you want because you have a lightsaber!

Happy Building!


DarthCynue (author)2017-01-23


The Rambler (author)DarthCynue2017-01-24


WestonVlogs (author)2015-10-30

what are the sizes and the names for the parts, and the other stuff

The Rambler (author)WestonVlogs2015-11-02

I don't remember all of the "sizes and names for the parts, and the other stuff" but the names I do remember I have included in the instructable. Also, some of the names and sizing can be seen on the packaging in the pictures. I didn't include all of the sizes because it was largely determined by what I found comfortable in my hand and then I just found parts to fit that size. Plumbing is meant to work together as an interlocking system so it's fairly easy to start with one piece you like and find everything you need to fit it.

Johnt007871 (author)2015-10-06

Yours is definately sharper looking than mine. I may need to revisit my hilt :)

The Rambler (author)Johnt0078712015-10-06

Thanks! I like the hard drive motor/blade emitter on yours. It reminds me of Luke's lightsaber.

kylegilbert (author)2015-09-17

Very nice. Need to try this.

The Rambler (author)kylegilbert2015-09-18

You should! It's a really fun build and a good reason to wander the aisles of your local hardware store replying to helpful employees with, "No thanks I don't need any help. I'm just looking for lightsaber parts."

kylegilbert (author)The Rambler2015-09-20

Ha! Yeah, I know that feeling. :)

desertsniper (author)2015-09-18

Good job! pretty convincing.

mwatt1 (author)2015-09-18

Yes I did the origal where WW2 British truck wipers. but mine are just normal ones. lol

The Rambler (author)mwatt12015-09-18

I don't think anyone will notice, haha.

mwatt1 (author)2015-09-17

Realy good set of instructions to build a nice saber.

The Rambler (author)mwatt12015-09-18

Oh, and I meant to say, thank you.

The Rambler (author)mwatt12015-09-18

Nice! I like the ridges on the grip. Did you get those from windshield wipers? I think I read that's what they used originally.

fituro (author)2015-09-17

Nice prop.

The Rambler (author)fituro2015-09-18


About This Instructable




Bio: I like to think of myself as a renaissance man. I'm interested in a lot of things, but most importantly I'm interested in ... More »
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