Lightsaber Build

Based off additional feedback + research here is the build now:

Note: Costs are now split into Material and Parts costs. Material covers general materials needed to build the lightsaber and will not be included in the Lightsaber Part Cost. However should production be considered, Material Cost will be a fraction of the overall cost displayed.


Material Cost: $34.43

Electrical Tape, 1' per build, builds 22 Lightsabers: $2.48
http://www.lowes.com/pd_78453-98-2155_0__?productId=3129711

Lead-Free Solder, 16oz, goal would be 2oz per build: $26.97
http://www.lowes.com/pd_98977-743-333513___?productId=3819167&pl=1&Ntt=solder

(Optional)PVC Cement: $4.98
http://www.lowes.com/pd_23467-138-31018L___?productId=4750803&pl=1&Ntt=pvc+cement



Part Cost: $25.74

(1 Lightsaber Build) 4x AA Battery Holder*: $0.89
http://www.jameco.com/1/1/567-bh-343-1a-r-battery-holder-4-aa-wires.html

(1 Lightsaber Build) 10" Copper & Tin wire, 22 gauge: $2.49
http://www.jameco.com/1/1/50997-9313-9-r-10ft-white-22-awg-solid-hook-wire-10-ft.html

(1 Lightsaber Build) Push Button Switch: $1.75
http://www.jameco.com/webapp/wcs/stores/servlet/Product_10001_10001_315660_-1

(1 Lightsaber Build) Vibrating Motor: $1.95
http://www.jameco.com/webapp/wcs/stores/servlet/Product_10001_10001_2209043_-1

(1 lightsaber build) 50 LED set: $3.00
www.amazon.com/Bluecell-White-Electronic...Bright/dp/B005ONQ41W

(1 lightsaber build) 3' CPVC Tube, 1" diameter, 1/8" wall: $7.50
www.usplastic.com/catalog/item.aspx?itemid=25313&catid=554

(1 lightsaber build) 2' grey PVC Tube, 1-1/2" diameter, 1/8" wall: $2.20
www.usplastic.com/catalog/item.aspx?itemid=23979&catid=727

(1 lightsaber build) grey PVC Tube 1" cap: $0.32
www.usplastic.com/catalog/item.aspx?itemid=25211&catid=738

(1 lightsaber build) 1" PVC Union: $5.64
http://www.lowes.com/pd_188223-69305-511-14-112-112B___?productId=50160561&pl=1&Ntt=pvc+1%22+union


*Improved amount of batteries improves longevity and quality of the blade light. In addition it slides in and out of the hilt housing and has enough of a power source potential to allow for additional electronics to be added for those further interested in upgrades.

actually the metal hilts can be brought on planes but you have to show them to security etc...i know someone that works for saberforge and he brings his everywhere he goes. for last year's starwars celebration in san diego he was talking about the security checks, and said that once he pulled it out and showed them, everyone was wanting to get pictures with them and to play with them...

another way of sourcing most of the electronics (especially the soundboard) would be to buy one of those cheap $25 plastic sabers from walmart and cannibalize it...i've seen a few builds done that way....it will be interesting though to watch this thread and see what you come up with

Thank you very much. I did forget some parts of the build:

(1 Lightsaber build) 6.3 ohm resister: $1.00
http://www.surplussales.com/resistors/wirewound/WW51-99.html

(1 Lightsaber build) Male to Female stereo connector (2 of them): $2.50
http://www.sfcable.com/2015-SF-02.html


This brings the full build up to....
Material Cost: $34.43
Parts Cost: $29.34

I think I could reliably split the costs of materials down. A little leeway with finances to allow me room for material shortfall/taxes/shipping/sales changes, so rounding up AFTER the first build, would be about $50.00 as an investment cap. I have all of the tools. $50.00 would likely give me a few dollars extra which would account for tool wear/tear. None of this includes labor costs.

Now as to how it would hold up. It is basically a massive pvc pipe unfinished with buttons and vibration. While the pvc union between the handle and the blade would be a weak point, it tightens and done properly you would be able to use this as a home defense weapon as it will have real weight (~2lbs) but not too much. Since it is rigid pvc and I have taken the effort to make this modular, should a piece break, unlike the toy... you can easily replace/fix it. My 12 year old son has destroyed 3 lightsaber toys in the last year.

In addition, this could be painted/fixed/sold as a TOTJO Light Blade Core (As Lightsaber is trademarked), as a concept. Since none of this design is made by or referenced to actual lightsaber props or toys produced by trademark license holders, this could be made open domain (designs) and then anyone here could produce them for the community or others. All that is provided is a concept core and none of the artistic elements that adhere to any of the propriety artistic elements of the Star Wars franchise or holders is involved.

Why this is important....

Well, not everyone can reasonably afford a Star Wars prop lightsaber. I know my wife would have kittens if I asked her if it was ok to burn roughly $400 on a lightsaber prop. Religious reasons or not, there are cheaper ways to not only provide a core but also to provide something that many of us desire in a reasonable manner.

This Light Blade as I will now call it, would be designed by me for free for our community. The designs, how to make it, and instructions in detail would be provided, so no one person would be the "sole" builder, and anyone can make their own Light Blade. In addition, due to the durability and fixable nature of this device, along with its low cost... it is something that could be made for a community without profiteering. For example, I can make one for both of my children and myself for a cost rounding up to $150... and will likely cost pennies on the dollar (USD) to repair should my 12 and 13 year old children decide to pillage a forest with the Light Blades I made for them.

What I also like about this is that it allows for everyone to personally embellish their own Light Blade. The sections (blade and hilt) can also be made apart from each other and it is completely modifiable. Want to have a different color? Change the LED set up. Want to add metal to the hilt? It is only 1" wide and allows for a lot of stuff to be added to it.

Does the shinai weigh more or less the same as a Lightsaber? Until I'm not able to get one, I was thinking about buying a shinai to practice the Forms.

Shinai weigh up to about 510g and the PVC lightsaber will be around 726kg, rounding up.

Shinai weight: 47" length
http://www.e-bogu.com/Shinai-Kendo-Bamboo-Sword-s/18.htm

PVC Weight: 1" width x 4' length
https://flexpvc.com/Reference/PVCPipeSpecsRigid.shtml
Note: This does not include electronics or buttons or batteries, but assume another foot of PVC weight, balanced just below the cross guard medium.

Simple Diagram and overall look.


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