GOLDEN BLADED LIGHTSABER – Curtis Carkoon
*WEBMASTER Note* - I do not guarantee the availability of these parts, nor do I guarantee the results. I did not build this saber, so if you have any questions or problems, you are on your own. I STRONGLY advise that you gather up the components, and check that they fit together properly relative to each other, before you buy them!
I am not responsible for any bills, injury, or other costs that you may incur by following these directions. I'm providing this as a useful reference, and as a free public service. The only thing I ask is that if anyone does create a saber using this recipe, they give credit where credit is due. This design, while based on designs used in the Star Wars (tm) movies, is original.
Lightsaber (or "lightsabre") is a trademark of Lucasfilm, Ltd.
MATERIALS
Images by Baldwin Solid Brass Towel Ring #3544-263
First Watch Solid Brass 180 degree Door Viewer #2330
Classic Connections Plumbpak 1 ¼" x 6" Brass Plated
Slip Joint Extension Tube with Brass Nut #PP12PB
Duracell Battery
2 Rubber Grommets
Miscellaneous Brass/Chrome Scrap Fittings & Plumbing Pieces $3.98
Chrome Extension Tube (approximately 2" long) $1.00
2 ¼" Machine Bushing $0.68
RADIO SHACK STUFF:
Mini Momentary Pushbutton Switches #275-1547 (used 1 red)
Miniature 12-volt Lamps 60mA #272-1099 (used 1 yellow)
Battery Holder
WAL-MART/HOBBY STORE STUFF:
Devcon High Strength 5-minute Fast Drying Epoxy #S-208 $1.97
Metal D Rings – Gold 1"-38D (used 1) $1.35
BASIC BLUEPRINT INSTRUCTIONS
Epoxy a scrap chrome extension piece inside the brass extension tube. Only 1" of chrome should be left exposed. The brass nut should already be screwed onto the brass extension tube before gluing.
Drill a hole (the size of your pushbutton switch) into the middle of one side of the 2" chrome extension tube. Wire the battery holder, miniature lamp (color of your choice), and pushbutton switch together and verify functionality.
Epoxy the chrome extension tube (approximately 2" long) over the top of the brass tube. Another brass nut should already be screwed onto the bottom portion of the chrome extender that slips over the brass tube. Verify that the chrome tube is level before the epoxy dries.
Epoxy the base of the door viewer to the top of the chrome extension tube. A washer may be glued to the top of the chrome extension tube to allow for more surface area in which to glue the base of the door viewer.
Insert switch, battery holder (with battery) and the lamp through the top of the saber hilt. Extend the switch through the drilled hole and screw down. The lamp should be exposed at the top. A small mounting structure can also be built to house the light nicely in the middle.
Apply your scrap emitter pieces (brass and chrome, some likely glued together) over the threads of the top portion of the door viewer and screw down. These pieces are left to your discretion and personal preference. I used a scrap chrome piece and a machine bushing for the conducting plate. The screw-down feature will allow you to access the battery or lamp for future replacement.
Assemble the mounting portion of the towel ring. Insert a rubber grommet into each side of the towel ring hole and then insert the metal D ring. The rubber grommets keep the metal D ring from clanging inside the towel ring hole when the saber is moved around.
Epoxy the towel ring to the base of the saber and allow to dry. A brass plated cap or other metal piece may be added to the towel ring to allow for more surface area in order to glue it to bottom chrome piece.
There is no paint involved, so for maintenance purposes simply wipe it down with a cloth diaper to remove fingerprints.
My advice is to look at several example sabers and develop a design that is unique to you. Looking for useable pieces that fit together is the most time consuming yet most rewarding part of lightsaber construction. A Jedi does not buy a pre-constructed lightsaber (that is the quick and easy path) unless he has already successfully created at least one on his own. Spend the time to find the perfect parts that fit together in a way that is pleasing to you, and construct something that you will be proud to call your own. Good luck, and may the Force be with you.
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