Things You'll Need:
- (1) Foot Long Chrome Tube, 1 1/4" in diameter
- (1) PVC Coupler; 1 1/4" diameter and 2" long
- (1) PVC End Cap; 1 1/4" diameter and 1 1/4" long
- Glossy Black Latex Paint, 1/2 Pint
- Clean Bucket
- Weather Stripping; High-Density and Self-Sticking that is 36" L x 1/2" W and 5/16" Thick
- (1) D-Ring
- (2) Eye Bolts, 8-32 by 1/2"
- (2) Locking Nuts; Plastic-Lined, Big Enough to fit Eye Bolts
- (2) 8-32 Hexagonal Nuts
- (2) Washers
- (2) Lock Washers
- (1) Fender Washer, 1 1/16" diameter
- (1) Electron Tube, 1 1/16" diameter
- (2) Nickel-Plated Caps
- (1) Length of Threated Tube to fit Caps
- (1) 10-Led Power Bar
- Various Small Screws
- Epoxy Glue
- (1) Extra-Bright LED; Large, rated for 2.7 volts
- (1) Battery Holder, AAA-Size
- (1) Single Pole/Single Throw Subminiature Switch
- (2) Batteries; AAA, 1.5V
- Electrical Wire; 12" and Stranded
- Electronics Wire
- LED Mount
- Hack Saw
- Screwdrivers
- Power Drill
- Pliers with Channel Locks
- Steel File, Rounded
- Aluminum Shears
- Vice
- Soldering Iron
- Solder
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Step 1
Using your saw cut a piece of chrome tubing that is at least 12" long but between 14" long.
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Step 2
Starting at 1/4" from an end of the chrome tube wrap the insulation around it until you reach your desired grip length.
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Step 3
Cut PVC cap in half and place on the end of the chrome tube where you left the space. Repeat with top of chrome tube and the other half of the PVC cap. Insert the screws to secure PVC caps in place.
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Step 4
Make a the size of the length of the LED by cutting it into the pipe.
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Step 5
Use your electric drill and make two holes for the nickel-plated caps.
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Step 6
Make the ends of the chrome tubes angled by cutting the ends off at identical angles. De-burr the metal with the knife.
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Step 7
Put the D-Ring in a vice and pull the ends apart. Place an eye hook on each end then press the ends of the D-Ring back together. Put the locking nuts on the eye hooks.
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Step 8
Remove the end cap and drill two holes into it close to the sides. Place the ends of the eye hooks in the holes in the end cap and attach with the fender washers then secure with lock washers and hex nuts. Remove from end cap and reassemble for later.
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Step 9
Remove the end cap and dip it in the paint can and let the excess paint drip off the hang to dry. continue until all PVC parts of painted and dry. Allow to dry before adding a second coat. Wait a day prior to attaching the PVC pieces to the pipe.
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Step 10
Glue the nickel-plated caps to the chrome tube placing one close to the front (near to the angled PVC pipe) and the other cap wherever you like it.
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Step 11
Rough up the bottom of the LED power bar with the dremel tool then epoxy it into place.
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Step 12
Take off the plastic base as well as the metal pins from the electron tube. Paint a thin layer of glue over the bulb then insert it into the front of the lightsaber until it lines up with the LED power bar.
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Step 1
Drill a hole into the chrome pipe large enough to fit the switch inside.
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Step 2
Connect the positive of the battery pack to the switch and run a wire from the other connector to the positive lead (normally longer) on the LED bar. Attach a wire from the to the negative lead on the LED to the negative side of the battery pack. Test the switch. if it does not work then you have the leads reversed.
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Step 3
Insulate the bare wires with electrical tape.
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Step 4
Slide the LED assembly into the chrome tube and slide the switch into the hole you drilled for it.
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Step 5
Slide the battery pack into the tube behind the LED assembly.
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Step 6
Replace the rear assembly and secure with the screws.
Comments
hallboy said
on 2/15/2009 sweet!