Star Wars Lightsaber Pool Cues/Hilts

A long time ago in a galaxy far, far away...
OR
Currently printing on your 3D printer right down the hall...

(Crawling text)

This Instructable will show you how to 3D print and assemble your very own Star Wars Lightsaber Cue Stick. I wanted to design something original and combine a few interests of mine. That being said, I decided to combine my favorite movie saga, Star Wars, with my favorite pass time, playing pool.

GOALS:

• Design something original.
• Use Fusion 360 for the first time somewhere in this project.
• Design the hilt so that every piece could be printed by any 3D printer with a minimum build size of 3" x 8".
• Share any interesting things I discover while writing this Instructable

NOTE:

• I have to say right from the start that I designed these cues for ease of constructing. These pool cues are probably not be rigid enough to play pool with.

Step 1: Materials and Equipment

Purchase/gather the following items:

Materials:

• Chosen Lightsaber Hilt Files - FREE
• Pool Cue Shaft Files - FREE
• Colored Cast Acrylic Rod (1" Dia.) (48" Long) - $35.75
• Clear Tube (1/4" ID) (5/16" OD) - $9.60
• Dowel Pins (3/32" Dia.) (3/8" Long) - $3.29
• Pool Cue Ferrules (Screw-In) (12mm) - $7.69
• Pool Cue Tips (Screw-On) (12mm) - $6.79
• EL Wire Power Supply (AA Driver) - $7.95
• 5mm EL Wire (3') (Green) (Master Yoda) - $17.94
• 5mm EL Wire (5') (Red) (Darth Vadar) - $21.24
• 5mm EL Wire (5') (Blue) (Luke Skywalker) - $21.24
• 5mm EL Wire (5') (Purple) (Mace Windu) - $21.24

Equipment:

• Tape
• Scissors
• Batteries
• Hot Glue Gun
• Measuring Tape
• Drill and 3/32" Drill Bit
• 3D Printer & Filament

NOTES:

• Make sure to purchase the TRANSPARENT Acrylic Rod and NOT TRANSLUCENT.
• If you use different material than what I have listed above then the STL files may need altered.
• If you do not own a 3D printer then you can always get them printed at Shapeways.

Step 2: Master Yodas Hilt Files

Download the attached compressed folder to make your own Master Yoda Lightsaber Pool Cue.

• Print the 4 STL files and move on to STEP 6 if you are eager to get building. I have also included a STEP file of the hilt in one solid piece for those who want to make their lightsaber pool cue one of a kind.

NOTE:

• If you don't want to make a Master Yoda Lightsaber Pool Cue then proceed to STEP 3.

Step 3: Luke Skywalkers Hilt Files

Download the attached compressed folder to make your own Luke Skywalker Lightsaber Pool Cue.

• Print the 4 STL files and move on to STEP 6 if you are eager to get building. I have also included a STEP file of the hilt in one solid piece for those who want to make their lightsaber pool cue one of a kind.

NOTE:

• If you don't want to make a Luke Skywalker Lightsaber Pool Cue then proceed to STEP 4.

Step 4: Darth Vadars Hilt Files

Download the attached compressed folder to make your own Darth Vader Lightsaber Pool Cue.

• Print the 4 STL files and move on to STEP 6 if you are eager to get building. I have also included a STEP file of the hilt in one solid piece for those who want to make their lightsaber pool cue one of a kind.

NOTE:

• If you don't want to make a Darth Vader Lightsaber Pool Cue then proceed to STEP 5.

Step 5: Mace Windus Hilt Files

Download the attached compressed folder to make your own Mace Windu Lightsaber Pool Cue.

• Print the 4 STL files and move on to STEP 6 if you are eager to get building. I have also included a STEP file of the hilt in one solid piece for those who want to make their lightsaber pool cue one of a kind.

NOTE:

• If you don't want to make a Mace Windu Lightsaber Pool Cue then proceed reading the rest of this Instructable and give me any feedback you might have.

Step 6: Pool Shaft Files

Download the attached PDF and send it to your local machine shop for a quote.

• Send the 34 Inch Machined Rod PDF if you are making a Master Yoda's Lightsaber Pool Cue.
• Send the 46 Inch Machined Rod PDF if you are making a Darth Vadar's, Luke Skywalker's, and/or Mace Windu's Lightsaber Pool Cue.

NOTE:

• Not every shop has the ability to produce these parts. If you receive an email back with a "no quote" then ask them if they know of another local shop that may be able to help.

Step 7: Cue Shaft

Permanently insert the tube into the rod.

• Cut a 34.75" length of tube if you are constructing Master Yoda's Lightsaber Pool Cue. Cut a 46.75" length of tube if you are creating any of the other three Lightsaber Pool Cues.
• Apply a 0.75" section of tape 0.75" from the top of the tube and a 0.75" section flush with the bottom of the tube.
  • (Apply enough tape at both locations so that the tube fits snug in the rod, the outer diameter should be approximately 0.375".) (Look at IMAGE 1 of this step for visual aid)
• Now insert the tube through the colored rod but leave approximately 1" or the tube outside of the bottom of the rod.
  • (Please note that I'm referring to the end of the rod with the largest diameter as the bottom.) (See IMAGE 2 of this step)
• Apply a thin layer of glue around the exposed tape.
• Slide the exposed end of the tube back into the rod so that you have access to the other section of tape.
  • (See IMAGE 3 of this step)
• Apply a thin layer of glue around the exposed tape.
• Finally, slide the tube back into the rod so that the tube is flush with the bottom of the rod and let the glue dry.
  • (See IMAGE 4 of this step)

NOTE:

• You could use a variety of different materials instead of tape. I only suggest tape because its a common household material.

Step 8: EL Wire

Prepare the EL wire.

• Simply cut the EL wire so that the colored wire is as long as the tube, either 34" or 46".
• Next, place a bead of hot glue on the cut end of the EL wire and let it cool.

NOTE:

• (Try to limit the size of the bead of glue to no larger than the diameter of the EL wire.)

Step 9: Assemble Two Halves of Your Hilt

Assemble PART 1 and PART 2 of the printed hilt.

• Check each connecting hole with a dowel to ensure the dowel pins fit snug.
  • (If a hole is too small to accept the dowel then use the drill and a 3/32" drill bit to extend the hole diameter. Repeat this process for every hole.)
• Apply a bead of glue to one end of a dowel and insert the glued end into PART 1 as far as you can.
  • (Insert the dowel into one of the holes that will line up with a hole in PART 2.)
• Next, apply a bead of glue to one end of a dowel and insert the glued end into PART 2 as far as you can.
  • (Insert the dowel into the other hole that will line up with its respected hole in PART 1.)

Assembly PART 3 and PART 4 of the printed hilt.

• Repeat the steps above for assembling PART 3 and PART 4 together.

NOTES:

• DO NOT ASSEMBLY THE TOP AND BOTTOM HALVES TOGETHER YET

Step 10: Battery Pack and Rod

Insert the battery pack and the rod assembly in its final position.

• Insert the batteries in the battery pack.
• Insert the battery pack in one of the hilt halves you created during the last step.
  • (See IMAGE 1 of this step)
• Feed the glued end of the EL wire through the rod assembly from STEP 7 as far as you can.
• Apply a thin layer of glue on the bottom 0.75" of the rod.
• Insert the bottom of the rod in the hilt half that you placed the battery pack in.
  • (See IMAGE 2 of this step)
• Connect the end of the battery pack wire to the end of the EL wire.
• Make sure all of the excess wire is contained within the printed tube like section in the hilt.

NOTE:

• You may need to use tape to secure the wire from unraveling out of its designated section

Step 11: Two Hilt Halves

Assembly both hilt halves.

• Perform steps similar to STEP 9.
• Check each connecting hole with a dowel to ensure the dowel pins fit snug.
  • (If a hole is too small to accept the dowel then use the drill and a 3/32" drill bit to extend the hole diameter. Repeat this process for every hole.)
• Apply a bead of glue to one end of a dowel and insert the glued end all the way into one of the holes located on the left side of the hilt half.
• Repeat the above process until all of the holes on the left side of the hilt half have dowels in them.
• Perform similar steps for the right side of the hilt half. However, this time make sure that the glued end of the dowel is inserted into the other hilt half.

Step 12: Conclusion

You have officially made a Lightsaber Pool Cue!

You can now start painting your hilt or you can find the perfect location to show your creation off. Don't forget to go back and make the other three Lightsaber Pool Cues!

REFLECTIONS/COMMENTS:

• This project was a lot of fun.
• I thought of a few other interesting ideas while working on this project. I don't want to give too much information away but I can say a Game of Thrones inspired idea came to mind.
• Fusion 360: I'm doing every hobbyist a favor by telling you that this product has everything a hobbyist wants. You can perform several different commands just by clicking and dragging the cursor in any direction! That feature alone had my attention. The layout is very clean and you can quickly toggle through the history of your part. The full use of Fusion 360 is FREE for "students, enthusiasts, hobbyists, and startups" as long as you need it!!! Everyone needs to give this product a chance. Visit the Fusion 360 website and download the trial. Once you're in you can register for free use.
• While working on this product I also discovered and learned more about Shapeways. I never really knew of any 3D printing shops and I never would have thought about looking for one if I didn't start looking into the companies that joined with Instructables to make a few contests. Anyone who doesn't own a 3D printer can get their parts printed in 50+ materials by visiting Shapeways website!
• The other company I decided to look more into after hearing their name was 3Dconnexion. This company has several products including a 3D Mouse! This is another product that I never would have thought to look into if I didn't start looking into the different companies that joined with Instructables for a contest. Without getting into too much details, this company has created a unique mouse that allows anyone who uses CAD to work more efficiently and more comfortably. Check out the 3Dconnexion website too if you get a chance.