Make your own lightsaber!

Make your own lightsaber!
Lightsabers! Use the Force and become a Jedi .... or a Sith!

This project comes from Parts and Crafts, developed from 2008 - 2011. Parts and Crafts is a creative community & summer camp for children to learn in an environment in which they are freely able to choose what they are doing. Parts and Crafts grew out of a camp I started in 2006 called Camp Kaleidoscope, which I directed through 2008.

The lightsaber kit was conceived of at Camp Kaleidoscope in 2008, and has since gone through several revisions by Parts and Crafts. We've tried it out in several public workshops, where children as young as 6 or 7, as well as parents and adults, have tried and generally loved the project. The project serves as both a reasonable introduction to electronics -- as it requires no prior knowledge -- as well as a fun way to explore making electronic props for costumes (especially for Halloween!)

We now have a kit available containing all the necessary parts at http://www.lightsaberkit.com

And for those interested, here's a blog post from 2008 when I was running Camp Kaleidoscope, telling a few stories I saw around kids making lightsabers and what I saw them learning in the process.
 
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Step 1Tools & Materials

Tools & Materials
Tools:

-PVC cutter
-hack-saw
-drill
-soldering set-up (you can probably get by without this, but it'll make the electronics section way easier.)

Materials:

HANDLE:
- 1.25" diameter PVC or larger, roughly 8 - 12 inches (any length that's comfortable.)
- push on  push off button, or switch
- battery pack (between 2 - 4 AA batteries)

(optional):

- silver spray paint
- bike inner tubes
- small motor (for making vibrations in the handle, and thus the awesome lightsaber sound effects!)

BLADE:

- polycarbonate tube. The outer diameter should be at least .75" and less than the inner diameter of the handle. Should be roughly 2.5 ft. long, scaled to size of future Jedi.

- 25 to 35 LEDs of desired color

- solid wire (22 gauge).

Total length = length of handle + length of blade + 3 inches

Notes on using different materials:

There are lots of different materials that can make this project work!

For handles, any tubular material of the right length and comfortable thickness will work. One padawan at camp used a handle from a scooter and it worked great. We also figured that tennis racket handles could work, and that we could make handles out of clay if we needed to, but we never tried these out.

For blades, opaque is better than clear because the light
must be diffused. So, basically any long, light, and stiff material that allows light through would work well for a blade.
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131 comments
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Oct 16, 2011. 2:59 PMRobot Lover says:
If you paint the LEDs black with some spray paint, it will diffuse them and it will distribute the light emitted from the LEDs better.
Jan 12, 2011. 8:45 PMmarcelo-fire_wing says:
cara ao inves de usar pilhas voce poderia usar uma raquete mata mosquitos a imagen ficol muito ruin eu sei e que usando o cabo da raquete fica muito mais facil porque ja ten o botao de liga e desliga ,baterias e plugi para recarga
sabre de luz.jpg
Sep 20, 2011. 8:02 AMsally300 says:
i think that is so cool
Jan 27, 2011. 12:49 PMcleage001 says:
(FAIL!) amigo tente em ingles que e uma lingua universal
marcelo-fire_wing said:
dude instead of batteries you could use a bug-killer racket the image stayed too bad i know its that using the racket's grip it becomes a lot easier because there is already the on/off switch batteries and recharge plugin(?) [sic]
(image)
não quis ofender, só é um fato...
Feb 3, 2011. 9:46 AMGramjen says:
This looks like a fantastic light saber to build! I have some friends whose kids spend hours making armor and weapons out of cardboard and duct tape. Though the mom may grimace a bit at adding light sabers to her home decor items they really are a great addition for the kids to play with and making them will certainly be educational.
Jan 27, 2011. 11:44 AMj4lmmfwcl says:
i got some EL wire from crazypc.com for like under 30 bucks (shipping and battery adapter included) and it worked great! (if anyone wants to kno)
Oct 22, 2010. 8:52 PMstevo1994 says:
How strong should the led's be?
Is like a 3900 mcd good? or would lower mcd ones work as good also?
Thanks!
Jul 26, 2009. 2:09 AMachannell1 says:
where can i find polycarbonate tubes?
Oct 22, 2010. 8:52 PMstevo1994 says:
A store called, "Tap Plastics" carries them. For about $1.10 a linear foot.
Sep 12, 2009. 10:10 AMweasel999 says:
Sep 12, 2009. 10:12 AMweasel999 says:
its probably a better idea to use a soldering iron to melt through the PVC
Oct 22, 2010. 3:48 PMKayla Ree says:
but it would smell really bad!
Oct 3, 2009. 10:30 AMred-king says:
toxic fumes....
Feb 15, 2010. 9:53 PMspaztec says:
 it's all good.
Feb 19, 2010. 1:42 PMred-king says:
as my father used to say: "It's all fun and games, until someone loses an eye." or in this case" It's all fun and games until someone breathes in toxic fumes.
Feb 19, 2010. 5:35 PMspaztec says:
 yeah, its all goo.
Oct 22, 2010. 12:36 PMvtheawesome says:
its a bit complicated isn't
Oct 11, 2010. 11:06 AMunlim1d says:
http://1cheat.ru/ - G8BK 4;O cs,G8BK 4;O cs source,'8BK 4;O aion,G8BK 4;O apb,G8BK 4;O samp,G8BK 4;O wow
Oct 11, 2010. 11:05 AMunlim1d says:
Very cool!
Dec 18, 2009. 3:31 AMdevinda says:
where can we buy clear polycarbonite tubes, exept for the site http//:polyzone.com
Dec 18, 2009. 9:57 PMblackchurch says:
Sep 3, 2010. 1:11 AMdevinda says:
I'm frm sri lanka. And my parents really don not like internet shopping for some reason. I did make a light saber and it did turn out really good. I got this transparent tube from a shop called shanti plastics in mountlavania and use sand paper on it.
Sep 9, 2010. 6:37 AMdevinda says:
srry my brother broke it. As i told i took a plastic clear tube,( it was around 2m long so i cut it) from shathi plastics. Check out http://www.shanthiplastic.com/. They i scarped it with sand paper. Then i took a pvc tube, cut it to the lenght i needed and i covered it in blue tape (also frm shanthi plastic) . then did the circuit and stuff and it works
Aug 22, 2010. 2:44 PMtechturtle2 says:
You can use EL wire for a seamless lightsabre
Aug 24, 2010. 6:28 AMMrTinkerer says:
EL is not that bright. Properly applied, LED is both cheaper and many, many, many, many times brighter than EL. And unless your diffuser is a tube of some sort EL will still have a seam.
Aug 9, 2010. 6:26 AMlord vader says:
does the lightsaber make sounds that sounds like a real one i just want to know because i have just started to build it.
Apr 2, 2010. 7:40 AMddi7i4d says:
 That is some cool stuff with LEDs, I made a lightsaber 2 years ago that uses reflection tape that glows when photographed with flash.
Lichtschwert1.jpg
Mar 31, 2010. 3:05 PMVick Jr says:
http://www.youtube.com/user/greytale

Check this guy out. He makes super high quality lightsabers with sound fonts and super-bright LEDs...and uses them in staged duels. His are much more complicated and expensive though.
Mar 31, 2010. 9:42 AMfloryzzz says:
 Nice work but one tip try at de inside of the cleatube some  paper it defuses the licht
Jan 4, 2010. 11:50 AMMadrias357 says:
If you use 1 inch PVC, you can use the Fluorescent bulb light tubes for your blade.  They'll fit over a coupler.

Yes, I've built one that way, just need an LED system to light it up.  There's also a ping-pong ball in the blade, the LED will be in the hilt: when in motion, the blade will light, but hold it up too long, the blade will retract.
Oct 20, 2009. 4:23 AMDangerGirl says:
I think I can make this...but was afraid the LED's would get disconnected or break if the impact were hard enough.  Somebody mentioned el wire....?  Is it as bright as the LED's?  What do u think?
Dec 18, 2009. 9:57 PMblackchurch says:
Nov 11, 2009. 5:52 PMsparky12345 says:
sweet! 
Oct 15, 2008. 3:24 PMsman17 says:
El wire works much better than LEd's. It is a wire that emits light and it won't blow out from the force of hitting lightsabers together like LED's will. Here are soem websites that sell El wire. I have also found it at rdioshack before.

http://www.save-on-crafts.com/neon.html?gclid=CLyKvueiqpYCFQ4RnQodM15jyw

http://www.elbestbuy.com/?gclid=CIW24viiqpYCFQGbnAoda1RUxw

http://www.thatscoolwire.com/?gclid=COzfjv6iqpYCFQpknAodr0uezA
Oct 3, 2009. 10:49 AMred-king says:
i think i've seen that stuff around before. i think you can get it at home hardware... or maybe it was canadian tire. not sure... one of the two though.
Oct 19, 2008. 10:13 AMjgeekw says:
I've got a friend who was doing small electronics for the navy, and he said that they used to build light beacons for helicopters out of clear tubing, fiber optics, and leds. This same process could be used for the saber blade as well. The good thing is that you could have the led board inside the hilt, then all the fiber would be in the blade. Viola! I'll see if he can draw me up some schims so you can see how they are built.
Oct 16, 2008. 11:14 PMArx says:
LEDs shouldn't blow out. Assuming you don't break the leads off, I expect they're tougher than EL wire.
Aug 9, 2010. 6:28 AMlord vader says:
solder them together
Oct 17, 2008. 11:01 AMsman17 says:
That's what I meant. I was at a comic book covention and people who make battle ready lightsabers such as these were there. The mastercrafter of the group said he worked with LED's and that after a little while they would burn out because the leads would get knocked around. EL wire iworks a lot better because there is nothing to break and the connections for the wire are in the handle. Just what he told me though.
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