Step 2: Grip and chamber cover

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.
<p>Are you selling any? I'm afraid I don't have the necessary tools at the moment.</p><p>Google Translate: Verkaufen Sie &uuml;berhaupt? Ich f&uuml;rchte, ich glaube nicht, im Moment haben die notwendigen Werkzeuge.</p>
could I possibly put alittle bit of blue and a little bit of yellow In between the green
I would just put a laser pointer behind the crystal, and put a telescoping, very solid!, tube with something at the top so that i could whack stuff with it.
Great tutorial! I'm currently following along to make a custom orange saber. May I ask what power source you used to power the string for testing? What voltage did you use?
that is awesom!!! 1 question how did you make the crystal??
I'm assuming the wiring for the LED strip goes through the sound board. What are the LED output specs of the sound board? Did you put any resistors on the LEDs? It seems they are wired in parallel, did you use only 1 resistor?
This is a great tutorial! but for those that dont know, the starwars light sabres in the first three movies where build from the Graflex 3 cell camera flash handles. (the ones made in the 40's that used replaceable bulbs after each picture was taken)<br><br>Ref: http://www.light-sabers.net/lightsaber-luke-props-origin01.html<br><br>but awesome tute dude!
Actually, Luke's sabers from New Hope and ESB were graflex flash gun handles. The Vader sabers from ANH and ESB were made from an MPP Flashgun, and Obi Wan's was made from a demilled WW1 british rifle grenade, an interconnect from a derwent jet engine, a graflex flash clamp, two unknown motorola military transistors, a machine gun muzzle booster from an ANM2 30 cal, and an armitage shanks sink knob. Also whatever mysterious hardware that was used to combine all those parts together. <br> <br>The Return of the Jedi sabers were cobbled together from the sabers from the previous movies, or completely made from scratch. <br> <br>I wish I had the prop guy's job back in the day, I bet that was lots of fun.
Yur totally right that would be awsome ill send u a photo of my rahm kota lightsabre hilt replica! :D
YEEEAAAAHHHH!!!! :))) <br>
i luke this
Superb. The farce is strong with this young jedi..
thats amazing ur really talented
Very cool. Your knowledge of Star Wars is impressive.<br>I believe John Mollo and Ivo Coveney were behind the props.<br>You may be interested in:<br>http://theswca.com/index.php?action=disp_item&amp;item_id=47482
Dude that is fantastic wish i had the machinery to build one. I hope someday we will have real lightsabers (i know that would be bad in the hands of the public and i can guarantee i would eventually maim myself or something else :P) buttt still total awesomeness
That is epic I've made replica lightsabers before but there is no comparison to yours. Nice Job
Beautiful workmanship! Fantastic Job!
This is great. Great drawing, and great finished finished product. Now someone just needs to work on the laser light so that you dont need the tube. Maybe one of the decades right?
i want to make one with a retraction blade, and effects so it looks like it's igniting. and sound for clashing, turning off/on, etc
Dammit I got drool all over my keyboard. Awesome project.
Can you cut off the limbs of idiots in cantinas? That's kind of a prerequisite for me...<br><br><br>Otherwise, looks awesome!
Awesome sabre! Please post a link for where to buy your nixie clocks.
The nixie stuff is at www.arduinix.com <br> <br>Thanks!
what were the approximate cost for all the materials?
I usually get my materials from onlinemetals.com, and I usually work in 6061 aircraft grade aluminum in either bar or tube at one and a half inch outside diameter. The aluminum is pretty cheap compared to the copper I used for the neck, that got expensive, but so worth it. <br> <br>The rechargeable batteries, soundcard, wiring, plugs and LEDs probably topped out around 200 bucks. The LEDs for the blade and chamber were around a buck a piece, and I used 94 of them in the saber.
Glad to finally see you on here sloth!!!
I see your Jedi skills are complete.
so you have completed your training as a padawan, now you are a JEDI MASTER!!!
To say that this is awesome is a total and complete understatement.
Wow! You're machining skills are insane! This and your other builds are astounding. I love the idea of actually using a crystal in the lightsaber. I love these kinds of projects but I don't have the skill or resources to machine things like that. I want to make a full metal suit of Halo armor personally but not sure how I would go about that at the present moment. I guess I'll just wait until I get my materials engineering degree and I'll just patent a new metal alloy and build my suit. That seems like a life goal there...<br>
Thanks, Puff! <br> <br>It's been a fun hobby. I will try and put more sabers on instructables, as well as some Nixie tube stuff. <br> <br>Brad
That is crazy awesome! Wonderful job!

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Bio: I am a 13 year veteran of the video game industry. In my spare time, I make nixie clocks and sell nixie clock kits, and ... More »
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