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Build a Lightsaber
by vv_767 on October 1, 2009 Table of Contents Build a Lightsaber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro: Build a Lightsaber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 1: Gallery - My Past Creations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 2: Parts and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 5 9
Step 3: Make Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 4: The Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Step 5: The Blade Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Step 6: The Hilt Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Step 7: Cutting the chrome sink tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Step 8: Intergrating the MHS with the sink tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Step 9: The Electronic Guts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Step 10: Electronics - Basic Lightsaber, NO sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Step 11: Enhanced Basic - LED Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Step 12: Basic with Basic Sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Step 13: Mid Level - Force FX Based . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Step 14: High Level - Ultra Sound Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Step 15: Premium - Erv's Crystal Focus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Step 16: Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
http://www.instructables.com/id/Building-a-Lightsaber/
Author:vv_767 ODST
I like making stuff when I have the time. But It is soooo hard to find TIME...
NOTE 1: This Instructable is very TEXT intensive. NOTE 2: Most of the parts used in this tutorial came from The Custom Saber Shop (TCSS). I am not affiliated or employed with them. I am just a customer. * The author of this instructable is not responsible for property damage, personal injury, amputation of limbs, decapitation, and/or death resulting from the building and use of the lightsaber prop. All legal responsibility or resulting civil action due to said property damage, personal injury, amputation of limbs, decapitation, and or death belongs solely to the builder. The author is also not responsible for anyone falling into the Dark Side. The author will also not be held responsible if an agent of the Dark side decides to fry you with lightning coming out of his/her fingertips*
Image Notes 1. Luxeon III RED 2. MR Darth Vader 3. ElectroLuminescent (EL) Aqua 4. Dual or Maul style ElectroLuminescent (EL) Blue
http://www.instructables.com/id/Building-a-Lightsaber/
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. Declaring my allegiance 2. My Less-than-authentic Jedi costume. 3. Yes, this was photoshop'd.
Image Notes 1. These brass accents used to be a sink tube. 2. These brass accents used to be a sink tube.
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. The lightsaber built for this instructable features a crystal chamber with a real quartz crystal. Here is a closer look at the chamber assembly.
http://www.instructables.com/id/Building-a-Lightsaber/
2. This is a stock Master Replica Darth Vader with the LED array in the blade. Not duel worthy as the array would break creating dark spots on the blade. 3. This was a test of 3 watt read led and a clear mylar film I was testing. LED and lense was not aligned so the blade was not evenly lit. That changed when installed into a hilt.
http://www.instructables.com/id/Building-a-Lightsaber/
http://www.instructables.com/id/Building-a-Lightsaber/
http://www.instructables.com/id/Building-a-Lightsaber/
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. This can be clear or frosted acrylic or polycarbonate. Glue to one end of the PC tube AFTER you attach a reflective surface on the flat side.
Image Notes 1. Polycarbonate Tube: Clear. 1" OD. 30-36 inches long.
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. Collimator. Get 5 or 10 degree. 2. Star with one LED emitter
Image Notes 1. This is a section of sink tube slipped over MHS parts after being shaped with a Dremel. 2. This is my warning label :p 3. Thumb screw 4. This is the switch 5. This is a section of sink tube cut and slipped over Blade holder style 12. 6. This is Blade holder style 12 7. this is a covertec button or stud. It snaps into a covertec belt clip (normally used to hold a PDA or cell phone)
http://www.instructables.com/id/Building-a-Lightsaber/
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. Blade inside blade holder 2. This brass screw holding this brass decorative plate is actually my blade retention screw.
Image Notes 1. Style 4 blade older 2. LED is mounted on this heatsink. 3. screws to hold the LED down
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. Style 8 2. This holds your LED star Image Notes 1. blade holder style 10. 2. It appears to be made of pure copper. It is heavy. I lapped mine to a mirror finish using wet sandpaper. Lapping is done with the following sandpaper grit 300, 600, 1000, 2000
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. Lightsaber build ENTIRELY from Modular Hilt System parts.
Image Notes 1. chrome sink tube 2. sink tube adapter 3. MHS Extension 4. chrome sink tube overlay/sleeve. 5. Blade holder 6. Pommel 7. MR Lightsaber Construction Kit 8. MR Lightsaber Construction Kit.
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. the sink tube has been cut to a design I had in mind.
Image Notes 1. The blade holder is on this end. 2. The MHS pipe adapter will be on this end Image Notes
http://www.instructables.com/id/Building-a-Lightsaber/
1. And the MHS parts are now inside the freshly cut sink tube.
Collect random parts. Keep them in a bin. Go get some thumb screws, LED bezels, leather studs/spikes, machines screws, etc. What ever you can think of to dress up your hilt body.
Image Notes 1. This is my "Junk" parts bin. Parts came from optical drives, hard drives, old vcr, dead dvd player, etc. 2. This is my "useful items" parts bin. It has switches, speakers, crystals, screws, motors, etc. 3. switches
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. Thumb screws look great on the lightsaber body 2. these are metal 5mm LED bezels. They look great on the lightsaber body. Even more so when the LEDs actually light up.
Try to get as much technical specs on the LED you want to use. A good example to start is here: http://www.philipslumileds.com/products/luxeonk2 Read the Datasheet . Important things to know about the LEDS are: 1. Minimum, normal, maximum Forward voltage. 2. Minimum, normal, and max Amperage 3. Light output in lumens at min, normal and max amperage 4. thermal management requirements 5. Size and mounting methods. Note that white, blue, and green take a higher forward voltage than red, yellow and amber. Also note that LEDs respond more to current than to voltage. Feeding your LED with current (milliamps) as close to what the datasheet states will provide the most optimal performance. Picture 1 shows my 3 REBELS mounted on one STAR. Besides the challenge of how to power these beast up was having a solution for the optics. Xwingband provided the solution by mounting the LED emitters as close as possible to each other and providing a collimator with a large enough opening underneath to ALMOST encompass all 3 Rebels. Picture 2 and 3 shows how the lense (collimator) would normally fit on top of a star with 1 LED emitter. Not shown is the Optics Holder which keeps the lense centered.
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. One Rebel 2. Two Rebel 3. Three Rebel 4. The LED emitters are connected in SERIES.
Image Notes 1. Collimator. Get 5 or 10 degree. 2. Star with one LED emitter
Image Notes 1. See how the LED emitter dome is INSIDE the collimator (aka, lense)
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. 700mAmp output 2. Each LED puts out 130 lumen @ 700 mA. i have the three connected in series so each LED is getting over 650 mA. That means I still have over 300 lumen total output. 3. 3.6v Li-ion battery. only three are being used to power the LEDs. the fourth is used to power the sound and accent LEDs. 3 bateries in series = 10.8v is being supplied to the BuckPuck
Image Notes 1. This is the microswitch used in the example saber. the amp rating of this tini switch is very low and it would melt if the power went through this from battery to LED. instead it is used as a "logic gate".
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. Push on/Push off. This switch is well suited for high amp usage. Image Notes 1. The LED under the Optics.
Image Notes 1. These are Normally Open (NO) switches. The circuit is ON when you push the button, BUT turns OFF the instant you let go. This is no good for a basic lightsaber but is used on the high end sound boards.
http://www.instructables.com/id/Building-a-Lightsaber/
How did I get purple? Well, I put 4.8 volts through the soundboard and split the positive wire going into the LEDs - one wire to the Blue LED and the other wire into a
http://www.instructables.com/id/Building-a-Lightsaber/
resistor then to the Red LED (remember, Red needs less voltage than Blue, hense the resistor). Both LEDs use a common Negative wire. Green was not used. Blue+Red = Purple. See Picture 2 on how to wire a Hasbro toy circuit board.
Image Notes 1. Hasbro Board. This board requires a Momentary (N.O.) switch.
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. Crystal Focus version ##.## 2. I did not want to give away Erv's secrets so the boards parts are pixelated.
http://www.instructables.com/id/Building-a-Lightsaber/
http://www.instructables.com/id/Building-a-Lightsaber/
Image Notes 1. Other than removing the background this picture was not photoshop'd. My lightsaber really was that bright.
Related Instructables
Make your own CR-Tutorials lightsaber! by Special-Star Wars 2/3nagle Lightsaber Effect (video) by ChemicalReaction
Comments
50 comments Add Comment view all 221 comments
whisper199 says:
id totally be on the DARKSIDE (dont forget the cookies) NOT!!!
mastermind14150 says:
i'm totally gonna do this for a no more heroes prop :3
kage_no_akiri says:
Jan 23, 2011. 8:33 PM REPLY wheres the boards on ultrasabers.com? i looked under the parts and suplies tab where you would THINK they would be kept...but there was nothing like this in the menu. all they have is battry holders, plugs, tips and the anikan gold activator button. at tcss all i found were speakers and sensors under sound kenkou ooku no seimi good health and long life
http://www.instructables.com/id/Building-a-Lightsaber/
pman123 says:
Jan 21, 2011. 5:07 PM REPLY Hey I was wondering about something...if I buy a pre-made and working lightsaber from ultrasabers.com, can I install sound? if so, where would I buy the supplies and how would I do it? I would buy a lightsaber with sound from them but they are about $400... Jan 16, 2011. 11:06 AM REPLY I have been looking into building my own lightsaber for some time now, and so far this looks very helpful, I have one question though, where did you purchase the LEDs? I can't seem to find them except in bulk from future lighting solutions.
dcatalystmx says:
vv_767 says:
Jan 17, 2011. 10:57 AM REPLY small quatity orders are possible from MANY internet sources. thecustomsabershop.com, DealExtreme.com, luxeonstar.com, ledsupply.com. Google is your friend.
Sergnation says:
So are these clash able, like some ones you can buy in store. just these are so bright.
vv_767 says:
Nov 18, 2010. 3:25 PM REPLY Yes, my lightsaber makes a clash and woosh sound when swinging and hitting, just like the $120 lightsabers in the store. Difference is that my blade will not break or crack from a heavy impact.
StArwArsN3rd says:
Nov 9, 2010. 6:54 PM REPLY Other than a buckpuck, what can u advice me to buy on a cheaper scale, and if you did buy it cheap where did you go if it's online?
vv_767 says:
Nov 10, 2010. 7:59 AM REPLY If you do not want to use a buckpuck, you can use the correct resistor control current and voltage to your LED. Resistors from radioshack is 3 bucks? If you want to go EVEN cheaper, figure out the voltage requirement of the LED and build a battery pack at or below that voltage. Example, if your LED requires 3.2 volts, two Alkaline AA batteries would deliver 3.0 volts, there you go.
StArwArsN3rd says:
Thank you but i think the 3 dollar resistor at Radioshack shall work, I'm cheap, just not that cheap.
vv_767 says:
Nov 11, 2010. 10:34 AM REPLY It is also a matter of efficiency. 3 volt battery pack powering a 3.2 volt led means all the voltage goes into powering the led. But 4.5 (3xAA) volts going into a resistor to drop voltage to 3.2 v for the led means the voltage difference is converted into heat in the resistor. The bigger the voltage difference, the more heat generated.
StArwArsN3rd says:
Nov 9, 2010. 6:26 PM REPLY Is there any way to make the hilt from scratch from buying the parts from a hardware store or is that the point of the last "Or" section in this step? i like to no so i dont go buy expensive parts that i could possibly find for cheaper else were.
vv_767 says:
Nov 10, 2010. 7:54 AM REPLY Yes, you can just buy a chrome sink tube and an assortment of PVC couplers, joints and pipes. We some creative engineering you can shape the PVC to hold the blade securely on the chrome sink tube.
mikethemaster123 says:
what lens did you use for the tri-star?
vv_767 says:
10 degree with an extra large opening at the bottom. Not sure where it came from. I got it as a kit with the star.
mikethemaster123 says:
Oct 27, 2010. 3:09 PM REPLY what website or do you have somewhere you could tell me about that has instructions on how to make a lightsaber with a metal lathe?
http://www.instructables.com/id/Building-a-Lightsaber/
vv_767 says:
Oct 27, 2010. 9:01 PM REPLY yahoo has a 7x12 lathe group. i learned a lot from them, but nothing specific to lightsabers. I am still a member of the group.
mikethemaster123 says:
any links?
vv_767 says:
Oct 29, 2010. 12:21 PM REPLY http://groups.yahoo.com/group/7x10minilathe/ -- less moderated http://groups.yahoo.com/group/7x12minilathe/ --- Moderated.
vv_767 says:
Oct 14, 2010. 7:19 AM REPLY hi Sasq23. Yeah, some of the old timers have moved on to other things since the market has cooled a bit. Right now Crystal Focus is is the only option. Some of the other sound board projects have died as well and never saw the light of day. Sorry, no isntructables on the crystal chamber as I feel is should be a total custom job. Basically, make it out of found objects around the house. On LEDs - Lambertian is a domed emitter lense so the light emission is conical. Side-emitting is just as it sounds, the light is redirected sideways, so the light looks like a donut when the LED is viewed from above.
Sasq23 says:
So I should go with a Lambertian then? or does it matter once you get the focusing lens on it?
vv_767 says:
use lambertian. side emitting and bat-wing will not work.
Sasq23 says:
Oct 13, 2010. 11:29 PM REPLY I was looking at the different Lux III LEd's and was wondering what's the difference between Lambertian and side side-emitting?
Sasq23 says:
And it looks like Xwingband AKA incomsabers.com is out of business as well. Does anybody make this cool stuff anymore?!!
Sasq23 says:
Oct 13, 2010. 6:54 PM REPLY They also stopped making the Ultra sound board 2.5. So what do we do if we don't want to settle for ripping the guts out of a toy?
Sasq23 says:
Can you/will you post instruction on how to build the crystal chamber? Or do you sell them?
Applerust says:
http://www.thecustomsabershop.com/ is down. Any other places we can get reliable parts?
vv_767 says:
The website was hacked. The owner of the store is working with his ISP to get the site restored.
vv_767 says:
The site is fixed. http://www.thecustomsabershop.com/default.aspx
vv_767 says:
(removed by author or community request)
Joeduke545 says:
I really really want one but it is too complex for me, You did an insanely good job with it
http://www.instructables.com/id/Building-a-Lightsaber/
amando96 says:
"The author of this instructable is not responsible for property damage, personal injury, amputation of limbs" So it works like the one in starwars?
vv_767 says:
Sep 27, 2010. 7:18 AM REPLY Yes, yes exactly like the one in Star Wars. I also have a Delorean in my garage that I just installed a Flux Capacitor in. jk ;) If I write an instructable about how to swing a broom handle around your well furnished living room, I would give the same disclaimer.
Verga says:
This is a must build, great pictures, and isntructions, going right intothe favorites
techturtle2 says:
NO ONE KNOWS HOW TO SPELL LIGHTSABRE!!! L-I-G-H-T-S-A-B-R-E that is how to spell it. -the grammar nazi
rciafardone says:
Sep 26, 2010. 2:56 PM REPLY If you were a real spell Nazi, you would know about the re-er thingy that happens in American English and British English. You come out instead as someone that does know neither Starwars lore nor proper english. Sep 26, 2010. 11:51 AM REPLY First off, Sabre and Saber are used interchangeably these days, unless you're talking about a specific given name. It's a British English vs. American English thing... Secondly, a Lightsaber is a created work of fiction, given that name with that spelling by its creator, so it is in fact spelled Lightsaber. Here's the Star Wars wikipedia entry: http://starwars.wikia.com/wiki/Lightsaber
Snapshot says:
rcisneros says:
LOL. You are absolutely correct. It's a name. If you want to spell your name with a Q and U and V, it's up to you.
vv_767 says:
L-I-G-H-T-S-A-B-E-R is how it is spelled in a galaxy far, far away ;).
Isn't lightsaber a made up word? Kind of like saying that Nissan made a spelling mistake when they created their luxury brand cars I-N-F-I-N-I-T-I?
bricabracwizard says:
It is a made up word but using conventional artifacts - Sabre (a sword) and made of light.
Snapshot says:
It's using the American English spelling, "Saber," not the traditional British English "Sabre."
dudeguy1234 says:
Sep 26, 2010. 7:13 AM REPLY All of the books, comics, and other extended-universe literature (as well as the scripts for the movies) spell it "Lightsaber".
brandon9271 says:
and If you Google "lightsabre" it says "Did you mean: LIGHTSABER?" I think that pretty much settles it ;)
bricabracwizard says:
Sep 26, 2010. 5:22 PM REPLY True, saber, not sabre, even on spellcheck it will not show sabre. I forgot how Americanized we all are, and it was an American film
Aeshir says:
Sep 26, 2010. 1:46 PM REPLY My brother and I each have a Darth Maul lightsaber from when we were kids when The Phantom Menace came out (*spits on floor*), a couple years ago I took the blades out and duct-taped the hilt to a Daisy pop-gun I have, under the barrel like a grenade launcher, but even with the end. The lightsaber has two buttons, one to turn it on for general use, and one to only charge up the capacitors so the next time you hit it, the lights will flash. So when I charge it up and fire my pop gun, I get a bang from the gun and a blinding flash of light out of the unshielded light. Not to mention the awesome whine of it capacitors being charged up before that. By the way, awesome instructable, broseph. I should turn that previous paragraph into an instructable. WOO SUNDAY! :D
http://www.instructables.com/id/Building-a-Lightsaber/
vv_767 says:
Aug 10, 2010. 7:36 AM REPLY I am not sure. Is there a hardware store there that carries plumming parts? Specifically, chrome sink tubes for bathroom sinks.
vv_767 says:
The specialty parts would be a harder to find. Things like the LED, polycarbonate tube, circuit board, film, and lense.
Just to give you an ideas of where the electronics come from - Crystal Focus is in UK, Ultraboard is in US, Makoto is in Japan. These guys are hobbiest who took their electronic skills to build lightsaber specific electronics to sell to us.
http://www.instructables.com/id/Building-a-Lightsaber/