How to Make a Lightsaber With Polly Plastics




Introduction: How to Make a Lightsaber With Polly Plastics

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Hello Cosplayers, Makers, Star Wars fans. See how Thomas makes a cool Lightsaber with common hardware and flashlight parts, along with Polly Plastics Moldable Plastic.

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Step 1: Watch the Video

Step 2: Gather Your Tools and Materials

  • Polly Plastics moldable plastic
  • 12 inch PVC drain extender
  • Sink drain replacement kit
  • Random parts (Thomas uses flashlight pieces, Super Soaker parts and metal washers in this build)
  • Rust-Oleum Hammered Enamel Paint
  • Rub ‘n Buff Wax Metallic Finish – silver and gold
  • Super Glue/ contact cement
  • Dremel tool
  • Hot glue gun with glue sticks
  • Cutting tools
  • Leather (optional)

Step 3: Assemble Your Parts

  • Draw a line on the PVC drain extender about 5” from the smooth end of the tube.
  • Use the Dremel to cut off the 5” piece.
  • Cut a rectangular slot through PVC part from the drain replacement kit.
  • Find your random parts that you can fit onto the PVC pipe. Here Thomas uses Super Soaker parts and flashlight parts. Attach with hot glue.
  • Heat ½ cup Polly Plastics moldable plastic, following the usage instructions, and use the molten Polly Plastic to secure your random parts to the PVC pipe and fill in any gaps.
  • Continue adding the rest of your random parts. Add enough moldable plastic to smooth and bevel all edges.
  • Insert the metal sink drain part into the end of the PVC slotted part.
  • Use Super Glue to glue any random metal parts onto other metal parts.

Step 4: Paint/Rub ‘n Buff

  • Use Rust-Oleum Hammered Enamel for the base coat for your lightsaber. Do not paint the metal sink drain part that fits into the PVC pipe.
  • Brush Rub ‘n Buff over the surface of the painted parts. Add a bit of water to the paste to make it easier to apply. Apply silver and gold to the get the look you want.

Step 5: Final Touches

  • Cut a piece of leather and attach it onto the lightsaber handle with contact cement.
  • Re-install the metal sink drain part unto the end of the lightsaber.

Step 6: Congrats!

Here is a picture of your finished Lightsaber.

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    That looks really nice. The next time that my son asks me for a toy light saber, I am just going to show him how to make his own.