How to Make a Lightsaber Hilt

Introduction: How to Make a Lightsaber Hilt

Instructions on how to build your own lightsaber hilt from Star Wars!

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Step 1: The Parts

All of the parts that I bought for the lightsaber I bought from three different stores and websites:

Step 2: The Parts Continued

Parts That I Used For My Lightsaber Hilt

  • 1-1/2" x 12" chrome plated brass sink tube
  • 1.5" sink tube adapter
  • Graflex replica red button thumb screw
  • A washer big enough to fit over the threaded end of the button
  • A bolt small enough to fit the button
  • Set of 6 piece 3.6" grips
  • Prophecy pommel

Step 3: The Supplies

Supplies I used:

  • Ruled paper
  • Pencil
  • Tape
  • Dremel
  • Medium grit sand paper tip for Dremel
  • Fiber glass reinforced cut-off wheel for Dremel

Step 4: Putting on the Grips

Try to apply these as even as possible and it even helps to put a thin piece of paper at the bottom just to make sure all of them are level.

Step 5: Putting on the Pommel

Screw the pommel into the sink tube adapter until it feels snug. Then you can use epoxy and fit the adapter into the hilt base.

Step 6: Designing the Blade Holder

This Step requires a piece of paper and a pencil. Using the diameter of the sink tube, draw out the shape using a ruler so that it will turn out as precise as possible. Once finished with designing, wrap the paper around the top of the tube and tape it so that it will stay in place for the next step.

Step 7: Drilling the Hole for the Button

For this step, use a drill to make a hole a little more than two of your hands from the bottom so that it will fit you perfectly.

Step 8: Cutting the Blade Holder

Using a fiber glass reinforced cut-off wheel accessory for a Dremel and follow the design from the last step. Don't attempt to cut the curves on the blade holder if there are any because that will be gone over with sand paper or a Dremel. With the rough outline of the blade holder, use a Dremel to make the edges curved and the lines smooth.

Step 9: The Button

For this stage of the process, all you have to do is stick your fingers inside of the saber hilt with the washer and place it over the hole you made earlier. Stick the button you have through the hole and the washer and then carefully screw the bolt on as tight as possible.

Step 10: FINISHED!!

From here, your lightsaber hilt is finished. You can deck it out with electronics and any other things you would like to add.

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    4 Discussions

    DIY Hacks and How Tos

    Great light saber base. This could be used to make a killer flashlight.


    Reply 4 years ago

    *killer* pun intended?


    Reply 4 years ago

    Haha thanks. You're so right!