Make your own lightsaber! by nagle
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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 1: 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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wui2615 says: Jan 28, 2013. 4:37 PM
Do you need to use resistors for this?
wui2615 says: Jan 28, 2013. 1:00 PM
when you were making the LEDs did you uses a resistor? and if you did what resister did you use?
devinda says: Dec 18, 2009. 3:31 AM
where can we buy clear polycarbonite tubes, exept for the site http//:polyzone.com
starbuck78 says: Sep 16, 2012. 11:30 AM
Petsmart in the fish section. They are usually tucked in the corner on the shelf with the pumps and hoses. Home Depot in the lighting department, they are used to protect those long florescent lights(not the strongest tubes,but ehh,if ll else fails. And most importantly Ultrasabers.com. You can buy a ready made blade that is just the right width and length and light diffusing properties. They go for about 30 bucks. But consider this. THe gas you will burn going to these different places,plus the items themselves;how much more is 30 bucks really? Now, the lightsabers are expensive as hell, but I think you can get one with no sound for less than 100 bucks and if you pick the right color, they're so bright they look real(as far as real goes concerning lightsabers). They do look good I bought a Bellicose Saber,red blade, flash on clash(it flashes silver when you lock sabers or hit sabers,looks cool) and sound that can be reprogrammed via usb cable plus expedited shipping. All the bells and whistles are extra, when all was said and done it was 300 bucks,but worth it. save up your money, don't burn it experimenting with diy projects that end up looking like a prison shank with Christmas lights, I know, I did it. Became obsessed, gave up said F*** it got online found ultrasabers,saved my money and got one.
Mr.Stein says: Mar 4, 2012. 10:03 PM
www.eplastics.com
blackchurch says: Dec 18, 2009. 9:57 PM
devinda says: Sep 3, 2010. 1:11 AM
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.
starbuck78 says: Sep 16, 2012. 11:39 AM
try a clear tube, then roll up cellophane until it looks silver then put it in the tube,not glad wrap, that thin sticky stuff, but the thicker stuff that people use to decorate. Use clear or that pearl colored clear I think its called iridescent or opalescent.. Trust me, it beats the Hell out of sandpaper.
nagle (author) says: Sep 6, 2010. 8:03 AM
hey! my mom is sri lankan! (and thus I'm half sri lankan.) i've been to mount lavinia. how neat! will you send me a picture of you with your lightsaber? i bet my mom would get a kick out of it. mpnagle at gmail dot com if you do want to. thanks!
devinda says: Sep 9, 2010. 6:37 AM
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
starbuck78 says: Sep 16, 2012. 11:40 AM
hey , perfect excuse to get that clear tube and cellophane!
Robot Lover says: Oct 16, 2011. 2:59 PM
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.
Pwag says: Jul 16, 2012. 10:57 PM
Black?
Robot Lover says: Jul 17, 2012. 8:27 PM
If you do not COMPLETELY cover it, but only finely spray them, they will defuse the light better. It came as a surprise for me, too.
Pwag says: Jul 17, 2012. 11:09 PM
I'd have figured white, I'll be damned.
h8864 says: Jul 15, 2012. 3:52 PM
i can use this for my melvin and florence lightsaber battles!!!!!


GO YGOTAS
nevia says: Jul 2, 2012. 5:52 AM
NASA studies have shown evidence that specific frequencies of light are responsible for growth in plants. NASA was maximizing the growth while minimizing their electrical use. In fact, many commercial growers are using this fact to save $ on their businesses. We'll go over the specific frequencies, where you can buy ready-made, how to make your own http://www.saberforge.com/
nevia says: Jul 2, 2012. 5:51 AM
NASA studies have shown evidence that specific frequencies of light are responsible for growth in plants. NASA was maximizing the growth while minimizing their electrical use. In fact, many commercial growers are using this fact to save $ on their businesses. We'll go over the specific frequencies, where you can buy ready-made, how to make your own/
jedi awsomness says: May 10, 2012. 5:48 PM
hey pleas mr.tinker could u follow me in messenger pleas my meesenger is fredycool2002@hotmail.com
cjudkins says: Mar 24, 2012. 8:58 AM
If my knowledge of a teenager is correct, it is possible to build a deadly (sorry, but it is true, is this not about the most famous deadly Star Wars weapon?) Lightsaber. First, in the handle, you need a laser pointer, a series of magnification glasses, then a tube that leads to a pole with copper wire inside and outside for the light to travel to and spreads around the pole.
monty324 says: Mar 4, 2012. 1:37 PM
this would look great with a rgb led strip in it connected to a switch that could pick a color or even, with the help of a microcrontroller, fade through difffrent colours
T-K says: Mar 4, 2012. 4:05 AM
Picked up a toy lightsaber today at Reverse Garbage, its not a legit branded one or anything, just a rip off. Although, I opened it up and inside the saber blade (which is made of translucent plastic like yours) is some kind of foam tubing shaped like an 'O', possibly foam gap filler rod. It helps diffuse the light a lot and probably protects the LEDs too. Love the motor idea!
imBobertRobert says: Mar 4, 2012. 7:17 AM
i 1+ this.
Runeshai says: Mar 4, 2012. 6:04 AM
Have you seen these: http://bigyellowbox.tripod.com/
Or this: http://www.slothfurnace.com/sabers/ROTJLuke_01.html

The first got me into making stuff in the first place back in the early 2000s, and that second one I just found the other day. There's a huge Star Wars fanfilm community online (check out TheForce.net/fanfilms). All of it's pretty inspiring.
achannell1 says: Jul 26, 2009. 2:09 AM
where can i find polycarbonate tubes?
Honestinwilkesbarre says: Feb 10, 2012. 5:51 AM
Any home improvement store, all the big boxers have them.
Ask for florescent light sleeves. They come in 48' Lengths, 1 1/2" diameter. They cost between $3 to $4 each.
stevo1994 says: Oct 22, 2010. 8:52 PM
A store called, "Tap Plastics" carries them. For about $1.10 a linear foot.
weasel999 says: Sep 12, 2009. 10:10 AM
marcelo-fire_wing says: Jan 12, 2011. 8:45 PM
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
sally300 says: Sep 20, 2011. 8:02 AM
i think that is so cool
cleage001 says: Jan 27, 2011. 12:49 PM
(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...
Gramjen says: Feb 3, 2011. 9:46 AM
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.
j4lmmfwcl says: Jan 27, 2011. 11:44 AM
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)
stevo1994 says: Oct 22, 2010. 8:52 PM
How strong should the led's be?
Is like a 3900 mcd good? or would lower mcd ones work as good also?
Thanks!
weasel999 says: Sep 12, 2009. 10:12 AM
its probably a better idea to use a soldering iron to melt through the PVC
Kayla Ree says: Oct 22, 2010. 3:48 PM
but it would smell really bad!
red-king says: Oct 3, 2009. 10:30 AM
toxic fumes....
spaztec says: Feb 15, 2010. 9:53 PM
 it's all good.
red-king says: Feb 19, 2010. 1:42 PM
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.
spaztec says: Feb 19, 2010. 5:35 PM
 yeah, its all goo.
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