There are plenty of instructables on how to build a light-saber out there, but I thought the uniqueness of this paint job was noteworthy, and wanted to share it. My friend is a RABID Texas Longhorn fan - and a Star Wars fan, so for his birthday I built him this saber. It took a couple tries to get the masking right, but all in all I am pretty happy with the results. For the Handle I started with just a white undercoat, then an orange layer, Cut the masking tape to the Longhorn shape - applied it, and painted black over the top. Then I dusted the whole thing with an orange overspray (to make it look slightly speckled). For the blade holder/emitter after the undercoat I painted it orange, masked the inside, and painted it black, then the orange over spray. Then I applied a Clearcoat over the whole thing to protect it.
For those of you who want to know, below are the paints and parts I used:
Black: Rust-Oleum Appliance Eboxy (Gloss Black)
White: Rust-Oleum Appliance Epoxy (Gloss White)
Orange: Rust-Oleum Gloss Protective Enamel
Clear-Coat: Rust-Oleum Crystal Clear Enamel
Hilt, All MHS parts from The Custom Saber Shop
LED is a Luxeon Tri-Star (402lm @ 700ma)
No driver (I could do that since the LED is run in series and the supply voltage is less then forward voltage, it means the LED is slightly dimmer than it could be)
Hope you enjoy!