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Author Topic: Jedi-Loreen's EL Lightsaber Blade Tutorial
Spongerd82 
Registered: Jan '05
23746_Duel
Date Posted: 2/22/05 5:19pm Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
What do you guys use for the blade holder inside the hilt? I am using a 5/8" blade but i can not find any thing that it will slide into snug. I am putting tape on the 4 inches that go inside the hilt to make it a bit larger. Any ideas would be great. An just so you guys know I have found that a 4 foot high bright el wire running on the hanl held inverters running at 9v is a littile bit brighter than the 7-10 foot of high bright el running on the pipsqeek at 9v. Plus it is cheaper.

 
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Kaladin 
Registered: Feb '05
23531_Royal Guard
Date Posted: 2/22/05 11:52pm Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial - Date Edited: 2/22/05 11:57pm (1 edits total) Edited By: Kaladin
Spongerd82,

Not knowing what the inside of your hilt looks like it is hard to say how to attach the blade, however assuming that it is a straight bore of either 3/4 of 1 diameter and assuming you want to hold the blade in with a thumb screw (I know a lot of assuming!)

What I would do is make an aluminum sleeve that is .003 o .005 clearance both over the blade and under the inside diameter of the hilt. And just drill a clearance hole slightly oversize for the thumb screw. That way the thumb screw would go through the adapter we are talking about and attach right into the blade. The adapter will hold the blade rigid and the screw will keep it from sliding in and out.

It should be easy to make one if you have access to a metal lathe, and if not, your local machine shop should be able to knock one out for you for about $15. (I am a designer for one myself)so if they want more than that they are trying to rip you off.

Hope this helps. And hope it is not getting to far into the area of hilts since this is a blade post!

And thanks for the tip on the acrylic half rounds, I just got mine in, they are sweet! Now I don't have to machine one.

 
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Aridus 
Registered: Nov '04
19918_R2-D2
Date Posted: 2/24/05 2:35pm Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial - Date Edited: 2/24/05 2:36pm (2 edits total) Edited By: Aridus
Just so its known, I have about 18 3/4" OD x 1/2" ID polycarbonate rods I need to get rid of (the company I ordered from screwed up my order, so I have a lot of extras). Contact me at randomactsofme@hotmail.com for the price if you want one. Thanks.

 
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Marianne_Solav  430 posts
Registered: Nov '01
13609_Rose Byrne
Date Posted: 3/1/05 6:30pm Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
Hi Loreen,

I'm trying to find some polyethylene tubing. When I look online, I often see H.D.P.E. and L.D.P.E. (High density polyethylene and low density).

Is there one better than the other? More or less translucent? I'm not sure what to choose...

And when you say 'rigid' polyethylene tubing, is that different than most polyethylene tubing?

Thanks! happy

 

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Kaladin 
Registered: Feb '05
23531_Royal Guard
Date Posted: 3/1/05 10:51pm Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial - Date Edited: 3/1/05 10:57pm (1 edits total) Edited By: Kaladin
I assembled my blade the other night, and it turned out awesome. Thanks again Jedi-Loreen!!

It was really bothering me that the diffuser tube was bent though, because it was bending the whole blade assembly. So before final assembly I hung the tube from the ceiling and heated it up evenly with a heat gun (a real hot hair dryer may work) and it relaxed the tubing making it very maleable. With the heat and just a little bending it while it was hot, I got the diffuser tube straight as an arrow. So now the blade does not have a bend in it at all. It turned out sweet.

 
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Rade_Konne 
Registered: Mar '05
23987_Darth Vader
Date Posted: 3/17/05 5:52pm Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
Awesome tutorial. I'm about to start constructing my own hilt and EL blade. I may be asking too much but is there any chance of adding pictures to enhance this tutorial and make sure I'm doing the right thing?

 
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Jedi-Loreen  2749 posts
Title: OCSWS Secretary
& Master of the Blades
 Registered: Dec '02
43743_Mara Jade
Date Posted: 3/18/05 12:37am Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
Uh, well, I don't have digital camera, and I haven't made any more blades lately. I have been asked about it before, though. I should try to do that, when I start making more blades for my friends.

Someone in the 501st was working on a photo tutorial last year, using my instructions, but I don't know what happened with it, if he ever finished and posted it. He had me look it over for my approval, which I gave him.

 

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In order to see the Light, you must sometimes risk the Darkness.
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Builder of EL Sabre Blades
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BescinPrix  203 posts
Registered: Oct '04
40001_Anakin
Date Posted: 3/18/05 4:21am Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
I should start construction of my blade within a few days, and if I can get a digital camera from a friend, I will be more than glad to send them to you, Jedi Loreen. It may not help anyone going to C#, but for future reference...

Also a questions, how long do you think that the total assembly of the blades takes?

 

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If you Fall, you must Fight;
If you Fight, you must Triumph;
If you Triumph you must avoid Falling again.
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Jedi-Loreen  2749 posts
Title: OCSWS Secretary
& Master of the Blades
 Registered: Dec '02
43743_Mara Jade
Date Posted: 3/18/05 12:36pm Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
Thank you for the offer. If you want to do that, then go for it, I'd like to see the pics you take.

I would say it should take about an hour to assemble one, depending on how much trouble you have with the EL wire, and the fact that the fine wires have a tendency to break when you are stripping or soldering.

Just remember, if you have the means, like is essential for me, keep testing the wire every step of the way to make sure it lights up. That way you will know right away of you have broken one of the wires inside. You don't want to find out after you have the whole thing put together that it's not working. doh! angry

 

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In order to see the Light, you must sometimes risk the Darkness.
"The Force is my Ally"
Builder of EL Sabre Blades
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BescinPrix  203 posts
Registered: Oct '04
40001_Anakin
Date Posted: 3/23/05 4:44am Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
Well, half my materials came last night.

I was impressed, I ordered everything Sunday night, and mid-morning Tuesday, all the tubing was at my front door. That is cooL!! McMaster rocks!!

I have a question for you, Jedi Loreen. Your diffuser tubing, is it clear colored (transparent/see-thru), or is it white? I expected it to be clear, but is white, and now I'm affraid that 1) I ordered the wrong thing, and 2) It won't be a bright blade at all. sad

Thanks!

 

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If you Fall, you must Fight;
If you Fight, you must Triumph;
If you Triumph you must avoid Falling again.
Mes compaingnons cui j'amoie et cui j'aim, . . . Me di, chanson
Companions whom I have loved and still do love... tell them my song
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Jedi-Loreen  2749 posts
Title: OCSWS Secretary
& Master of the Blades
 Registered: Dec '02
43743_Mara Jade
Date Posted: 3/23/05 11:57am Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
No, the diffuser tubing is supposed to be white. If it was clear, then it would have to be really "frosted" in order to provide the proper diffusion and hide the EL wire. When you have the wire inside it, it will create a nice, even glow thoughout the whole piece of tubing.

I tried about 6 different types of tubing before I found the one that had the diffusion properties I wanted. So don't worry, it sounds like you got the right tubing!

 

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In order to see the Light, you must sometimes risk the Darkness.
"The Force is my Ally"
Builder of EL Sabre Blades
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BescinPrix  203 posts
Registered: Oct '04
40001_Anakin
Date Posted: 3/23/05 12:10pm Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
Thanks Jedi Loreen I understand now!

Phew!! FOr a while there I thought I had messed up! happy

 

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If you Fall, you must Fight;
If you Fight, you must Triumph;
If you Triumph you must avoid Falling again.
Mes compaingnons cui j'amoie et cui j'aim, . . . Me di, chanson
Companions whom I have loved and still do love... tell them my song
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Jedi_Ranger_007  882 posts
Registered: Mar '04
6408_Jedi Outcast
Date Posted: 3/26/05 4:35am Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
Well, I have spent a lot of money and done much experimenting, and come to some conclusions. This comment is regarding possible diffusers.

After planning several different possibilities, I eventually decided on the white tubing, polyethelyne. I decided on this mostly to help fill in the empty space inside the polycarbonate tube (and THAT took a long time to find a decent dealer/location).

I personally prefer the 1/2" OD polyE, as apposed to the smaller (and seemingly more popular) 3/8" OD. The 1/2" fills the 3/4" polyC a little more, and gives a fuller look, when lit.

The high-brightness blades I have built look great, but from about 1 meter and closer, the individual strands can be seen. I am now thinking about adding a sheet of thin white tissue paper between the polyC "shell" and the polyE diffuser.

Another diffuser thought that I had toyed with, was using frosted sticker sheet, like that used to give an expensive frosted-look to clear windows. Sometime, I may still try this, just out of curiosity.

 

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Jedi-Loreen  2749 posts
Title: OCSWS Secretary
& Master of the Blades
 Registered: Dec '02
43743_Mara Jade
Date Posted: 3/26/05 3:14pm Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
I don't know of anyone using 3/8" OD diffuser tubing, I don't know where you came up with that. That would leave too little room inside it for the EL wire.

Sometimes, with the brighter EL wires, I have lightly sanded the outside of the diffuser tubing, that seems to help diffuse it a little more.

But I do like your idea of the frosted stickers. If you try that, let me know how it works out.

 

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In order to see the Light, you must sometimes risk the Darkness.
"The Force is my Ally"
Builder of EL Sabre Blades
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Jedi_Ranger_007  882 posts
Registered: Mar '04
6408_Jedi Outcast
Date Posted: 3/26/05 3:48pm Subject: RE: Jedi-Loreen's EL Lightsaber Blade Tutorial
Sorry, my bad. I didn't mean more popular here; I've just been reading TONS of different forums and posts and stuff, and mixed with my own experiments, got a little confused.

Hehe, maybe I should have waited till I had gotten some sleep, before making that post.

Anyway, now that I have gotten some sleep, I have gone back and reread your posts Jedi-Loreen, and it looks like we build our blades mostly the same.

Except for "bushings"; I prefer using 5/8" polyC. I find that using a second layer of polyE at the end seems to dim it a bit more.

I'm also still researching on a quick and easy way of mounting the hilt female receiver end of a mono/stereo jack. I think I'll go with coring a 1.5" OD wood dowling. I already use that to support my blades inside the hilt.

They friction-fit super tight around the polyC blade, and I just use a screw to hold the whole assembly inside the hilt. For now, I have just used a black allen hex-head (for cool factor of having to use tools on my lightsaber), but I'd like to switch to a nicer-looking thumbscrew with a larger head.

 

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