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Slothfurnace.com presents: The ROTJ Luke Skywalker Lightsaber

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Step 2: Grip and chamber cover

Picture of Grip and chamber cover
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For the ribbed grip section, I start with a 1.5 inch outside diameter tube of 6061 aircraft aluminum, with a one inch inside bore.  With it chucked up in my lathe, I mark light tooling marks on the outside at 0.32 inch intervals so I know where my grooves will go.

When my marks are done, I begin to cut grooves.  

I also leave a bit of material on the rear, so when I drill my template through that section, and cut it off, I will be left with proper holes in the grip section, and a piece of aluminum with corresponding holes I can use as a hole transfer template.
 
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