Two Hour Lightsaber

by Flintman in Workshop > Metalworking

2312 Views, 18 Favorites, 0 Comments

Two Hour Lightsaber

20211225_105930.jpg
Is it possible to build a quality Lightsaber in only 2 hours? If using modified existing parts, the answer is yes. I have gathered up a small box of "things" that were laying around my shop. By modifying any or all of these parts, a quality Lightsaber could be constructed in 2 hours.
This instructable will demonstrate how to build a quality Lightsaber from literally any found objects. This project will require a metal lathe and drill press plus a few hand tools....hacksaw, files, taps, etc.
Any young Padawan can dig around in the garage or basement and find enough interesting items to build a quality Lightsaber.

Supplies

A Box of Small Interesting Parts
Various Diameters of Scrap Aluminum and Brass
Metal Lathe
Drill Press
Drill bits
Hacksaw
Vise
Taps
6/32 Set Screws
Fine Sandpaper

Find Your Parts

20211220_142655.jpg
These parts were chosen from many 100's of items laying around my shop. If you can't find usable parts at home, dig around in friends garages or junk yards till you can aquire a nice selection.

Design Your Lightsaber

When you have enough parts, lay them out to see what can be done with them. I always like to start with the front emitter of a Lightsaber. As you are building, rearranging the original parts layout is often needed. Always remember, it's your Lightsaber. There is no right or wrong way to build it.

Front Emitter

20211220_143411.jpg
20211220_144214.jpg
20211220_144715.jpg
20211220_145419.jpg
The emitter will be the front section from a brass fire nozzle. About 2 inches of the end will work fine. Machine any markings or engravings off for a better look. Cut off and machine the other side.

Emitter Shaft

20211220_151500.jpg
20211220_151934.jpg
20211220_152027.jpg
20211220_155246.jpg
20211220_155403.jpg
20211220_155702.jpg
20211220_155824.jpg
20211220_155911.jpg
A 3 inch piece of 1-1/8 inch aluminum tubing is machined to tightly fit into the emitter. Press fit on a vise to permanently attach. Now machine a bushing from aluminum to tightly fit into the emitter shaft. Press into place for a permanent fit.

Emitter Core

20211220_152306.jpg
20211225_092346.jpg
20211225_083125.jpg
20211225_092514.jpg
Here is a small stainless steel pneumatic motor with a 5/32 inch chuck. This part is perfect as it fits tightly into the emitter and allows you to chuck something in for a finishing touch. Now you have the ability to remove and replace the tip to suit your needs.

Barrel Assembly

20211224_164106.jpg
20211224_164610.jpg
20211224_164738.jpg
20211224_165341.jpg
Machine the leftover knurled section of the fire nozzle for the barrel assembly. A 1-1/2 inch diameter brass gear is machined part way to fit into one end. Round over the other end of the gear for a nice transition. Press together for a permanent fit.

Handle

20211224_155909.jpg
20211224_160437.jpg
20211224_170339.jpg
20211224_171630.jpg
20211225_075950.jpg
The handle will be made from an old spring loaded grease tool. Remove the internal mechanism and give the outside a good sanding and polishing. Machine a brass bushing that will connect the handle to the barrel assembly. The handle and barrel assembly are then pressed together for a permanent fit.

Attaching the Handle

20211225_075858.jpg
20211225_075939.jpg
20211225_100228.jpg
20211225_101949.jpg
20211225_102016.jpg
20211225_102247.jpg
If you wanted a permanent fit, you would machine the emitter bushing shaft to be tight and then pressed into the handle. In this case however, the emitter bushing is machined to slide onto the handle. Drill (6) evenly spaced 7/64 inch holes on the emitter shaft and tap 6/32 threads. Now attach to the handle with (6) set screws. If you want to hide the mounting set screws, machine a brass collar with a snug fit. After the set screws are tighten, firmly slide the collar into place.
This method of attaching will allow for future upgrades if needed.

A Finishing Touch

20211225_105308.jpg
20211225_105316.jpg
20211225_110143.jpg
20211225_105807.jpg
I had parts to an old pair of binoculars and one of the brass eye pieces was a perfect fit. Just tight enough to remove and operate the drill chuck if needed but firmly stays in place.

A Finished Lightsaber

20211225_105930.jpg
20211225_105940.jpg
20211225_110143.jpg
20211225_092630.jpg
This Lightsaber project took 2 hours and 6 minutes to complete. The total length is a little over 10 inches and weighs about 2 pounds. Since the grease barrel had a screw off cap, you now have a nice storage area in the handle.
All steps can and should be modified depending upon what you have at your disposal. This instructable demonstrates the possibilities of using just about any collection of small parts to build a quick Lightsaber. In this version all fasteners are hidden for a sleek look.
Future refinements can be made at any time but this Lightsaber is ready for battle. "Make" believe battle that is....young Padawans.
MAY THE FORCE BE WITH YOU