I have always wanted a movie accurate lightsaber prop but cant get myself to spend outrageous amounts of money to get one, so i decided to build my own. I heard somewhere that the makers of Star Wars made the lightsaber hilts from random hardware and supplies, that is the route I took.

In this instructable I'm going to show you what I used to make my very own, realistic feeling lightsaber hilt.

Step 1: Parts and Tools

Parts:

2x EMT Connector 1 1/4 "
Compressor 1 1/4 "
Hose Connector
PVC pipe
D-ring
Nuts
Electrical Tape
Metal Pipe
Washers
Wire Connector

Tools:

Glue
Epoxy Resin
Handsaw
Screwdriver
Vice
Sandpaper (Optional)
Paint (Optional)

I obtained these parts at Home Depot. For customization, many different parts can be used for different looks as long as they are the right size.

Step 2: Making Sure Everything Fits

This step took me some time but while shopping for parts I had an idea of sandwiching every part together on one central rod stuck on my mind, so that is what I went for. I recommend double checking that everything fits in a visually appealing way before moving on.

I also had to cut the PVC pipe down to size so that the saber hilt wasn't too long.

Step 3: Connections

I used electrical tape to connect certain parts that didn't screw together or connect well. This secured them safely but also gave the saber a grip-looking material. glue can also be used to fasten parts together.

I connected the Compressor to the bottom EMT Connector as well as the Hose Connector to the top EMT Connector. These now serve as one piece.

I also covered the metal pipe with electrical tape since it would be the main grip of the hilt, also because the label was difficult to get off.

Step 4: Slide Everything Into Place

Now that the individual pieces are taken care of, they are ready to be put in place. Following the same layout I had in mind earlier, I slid all of the pieces into place. The electrical tape acted in my advantage because it made the fittings more secure.

Step 5: D-Ring/Hook

The D-Ring's holes do not align perfect with the EMT Connector so they will need to be modified. To do this I put it in a vice grip and used a drill to carefully edge away at the top side to widen the hole for the EMT screws.

This worked perfectly and gave the hilt a wonderful, real touch because it has a way to be fastened to a belt.

Step 6: Sealing All Parts Together

The reason I chose EMT Connectors is because they can be tightened by tightening the screws. This kept everything in place without the need of glue or more threads, and is also a very secure hold.

Also, the bottom of the hilt is an open hole, I used a washer and super glue to seal the end of it. And because the Compressor is threaded at the bottom, it can easily be removed for wiring if you want to take it further in the future.

Step 7: Button

To make the button I used a Wire Connector and a Nut. To do this, I cut the tip off the wire connector and repeatedly mashed it into the nut with a hammer. It seemed funny while I was doing it but it turned out phenomenal as a dummy button for looks. After the button was complete, I used Epoxy Resin to place it in the desired spot.

Step 8: Weathering and Finishing Touches

I chose to do minimal weathering because I'm not very skilled in that area. I used sandpaper to rough up and scratch some of the visible metal pieces that may take damage in use. I also used a blowtorch to singe certain areas up towards the emitter as if a hot, powerful laser blade would actually protrude out of it.

You can also use black paint and wipe it away with acetone to create a dirty look.

This is my final product of my personal Lightsaber Hilt!