How to Build an LED Lightsaber
Illuminated toy swords (based on the light sabers of George Lucas' Star Wars universe) have been popular playthings for the young and the young-at-heart for many years. However, buying one from a store can either be expensive, in the case of high quality movie merchandise, or disappointing, in the case of badly made copies. One solution is to make your own light saber, using LEDs and other relatively inexpensive parts.
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Things You'll Need
- 8-inch hollow aluminum tubing, approximately 2 inches in diameter
- 3-foot plastic tubing of slightly smaller diameter
- 3-foot, 6-inch dowelling
- Electrical tape in various colors
- Enamel or acrylic paints
- String of battery powered LED lights at least 6 feet in length
- Epoxy putty
- Drill
- Hacksaw
Instructions
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1
Cut away a section of the tube at one end, approximately 3 inches long and half the circumference of the tube. Measure the switch on the battery pack for the LED lights, and cut or drill an appropriately sized hole in the cut-away section of metal tube. Secure the battery pack in place under the cut-away section with electrical tape. Later you may wish to secure it more permanently but remember that you’ll need to change the batteries in the future.
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2
Mix the putty according to the manufacturer’s instructions and secure the dowel inside the tube. Ensure that the section with the battery pack fits back in place but don’t secure it yet. The dowel should be positioned centrally and must be straight, so you will need to support it in some way while the putty cures.
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3
Wind the string of LEDs in a spiral up the dowel. The more LEDs you have, the better the overall effect will be. Secure the wire at intervals with electrical tape. Use white or light-colored tape here so that it will not be visible through the outer casing.
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4
Cut the tube for the outer casing to the length of the dowel. Carefully melt and smooth the open end of the tube into a rounded shape, or close it with a section of the same or similar material. Slide the outer casing over the dowel and secure the end of it inside the aluminum tube with putty or tape. Replace the battery pack section and secure it.
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5
Decorate the handle of your light saber. You can create designs with strips of electrical tape. Use different colors of tape to achieve a variety of effects. Add fine details with hobby enamel or acrylic paints. Attach other decorations with glue or epoxy, if desired.
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Tips & Warnings
For the aluminum tubing, you can visit your local hardware store and purchase a
section of the right length, or use cycle parts and vacuum-cleaner accessories. Some broom or mop handles are made of aluminum; these tend to be lighter and thinner, and so less durable, but they are easier to cut. For the outer casing you need a finish that is uniform, and translucent but not transparent. It must diffuse the light from the LEDs and make it look as if there is one smooth light instead of lots of little ones.
