| Author |
Topic:
Machining Lightsaber Props
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FlamingRain
Registered:
Mar '08
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Date Posted:
3/19 4:20pm
Subject:
Machining Lightsaber Props
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For a fan film that I will be making during spring break in 2 weeks I wanted to get a prop hilt machined for me. Now I was going to go with the plastic ones but after practicing twice with them I busted one of them and couldnt repair them.
Now, I live in the middle of nowhere, and it takes almost forever (read 2 and 1/2 hours to get to Toys R Us, and the Walmart and Target out here dont carry the toy lightsabers, but we do have a hell of a lot of machine shops out here.
I have blueprints/schematics for them, and I realized: I don't have training on lathes and those types of equipment (although I have much training with woodworking lathes/equipment).
A few questions:
1 - How much would it cost / Would I even be able to get these props machined with no experience.
2 - If no to the 2nd question above, do most (MOST) machine shops take special orders?
3 - How do you secure the blade in (Obi Wan Kenobi ROTJ lightsaber)
Thanks very much, and I hope to be back here again.
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Evil-Henchman
Registered:
Jul '04
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Date Posted:
3/19 6:26pm
Subject:
RE: Machining Lightsaber Props
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FlamingRain posted:
For a fan film that I will be making during spring break in 2 weeks I wanted to get a prop hilt machined for me. Now I was going to go with the plastic ones but after practicing twice with them I busted one of them and couldnt repair them.
Now, I live in the middle of nowhere, and it takes almost forever (read 2 and 1/2 hours to get to Toys R Us, and the Walmart and Target out here dont carry the toy lightsabers, but we do have a hell of a lot of machine shops out here.
I have blueprints/schematics for them, and I realized: I don't have training on lathes and those types of equipment (although I have much training with woodworking lathes/equipment).
A few questions:
1 - How much would it cost / Would I even be able to get these props machined with no experience.
2 - If no to the 2nd question above, do most (MOST) machine shops take special orders?
3 - How do you secure the blade in (Obi Wan Kenobi ROTJ lightsaber)
Thanks very much, and I hope to be back here again.
1. That mainly depends on who makes it. Usually around $75 to $150 for one hilt. Price changes with difficulty and if the maker is installing electronics for you./That depends on how quick of a learner you are so my answer is maybe. Of course I doubt many shops are going to let you use their machines.
2. I have no idea, I have never looked into it. Sorry.
3. There is no such saber as Obi-Wan was a ghost in ROTJ. I'm assuming you meant a different movie in the series. Regardless, the easiest (but not neccessarily the prettiest) way to secure a blade in ANY saber is to use a bolt. Brass lamp screws (really a bolt) are what I usually use. They look alright. If the blade is too thin, build it up with some kind of tape like duct or electrical. If it would take quite a lot of tape to build it up, you might want a custom aluminum spacer or whatnot. Use a headless hex bolt (so that it can be sunk flush with the outer part of the spacer) to secure the blade in the spacer and then use a bolt to secure the spacer inside of the hilt. Remember, that the hole in the spacer or blade needs to be tapped to the proper thread for the bolt. If using pressure to hold it in then only the hilt and needs to be tapped (as well as the hole in the spacer that is used to pin the blade to the the inside of the spacer).
-----signature-----
"Warned you we tried. Listen you did not. Now screwed we all will be."
"Why are there no lumberjacks in the city?"
"Ninja kick the damn rabbit!"
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FlamingRain
Registered:
Mar '08
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Date Posted:
3/19 7:36pm
Subject:
RE: Machining Lightsaber Props
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Sorry, I meant Obi Wan ROTS, it was a custom designed schematic, it looks more like luke's ROTJ, furthermore, I will secure it in with the bolt, however, if I wanted to hollow it out what would I do? (sorry for all the questions  )
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Evil-Henchman
Registered:
Jul '04
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Date Posted:
3/19 9:38pm
Subject:
RE: Machining Lightsaber Props
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If you are wanting to hollow out a solid saber that cannot be split in half vertically then you would need to secure the hilt in a vise and bore it out with a drill or drill press. Alternatively you might be able to secure the hilt in a lathe (but not likely if it doesn't come apart in any way) and bore it out that way. Either method is likely to put some nasty marks/dents on the hilt but if you wrap the hilt in cloth before putting it in the vise, you will probably be ok (I've also put a few layers of duct tape on a finished piece and put it back on the lathe to do more work on it. Works like a charm). If it opens up in half vertically (like the Hasbro toy sabers) you could use various bits on a rotary tool (like the Dremel brand) to hollow it out further. I hope that helps.
Oh and please check your PMs (private messages) as I sent you one.
-----signature-----
"Warned you we tried. Listen you did not. Now screwed we all will be."
"Why are there no lumberjacks in the city?"
"Ninja kick the damn rabbit!"
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Siths_Herald
Title: Minnesota CR
MNFF Co-Leader
Registered:
Jan '04
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Date Posted:
3/24 12:48pm
Subject:
RE: Machining Lightsaber Props
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I've built a couple prop hilts. Though they do not accept blades (maybe generation II will) I did most of the work on a lathe. If you want to hollow out a chunk of aluminum, the lathe is going to be the best way to get a true and concentric bore. If you're concerned about marks on the outside, overcome this by planning ahead and boring out the center first, then do the outside details.
Unfortunatly, I no longer have easy access to a lathe, but any small machine shop should do the work as long as you're paying. I doubt they care if the parts are for a prop or for a space shuttle as long as they can get their time, material and some profit out of it. Where you may pay more for extra details on a prop, you might save some since the tolerances are not critical (unless you are machining mating parts.)
Good luck!
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Hapajedi
Registered:
Dec '00
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Date Posted:
3/24 2:50pm
Subject:
RE: Machining Lightsaber Props
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One of my original custom creations, machined out of solid aluminum round,tubing. Blending Darth Maul's double and Qui Gon Jinn's hilt designs in mind.
After going over numerous re-designs with the martial artist wielding this menace
Here are an example of mine just done
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"All we have to decide is what to do with the time that is given to us"
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FlamingRain
Registered:
Mar '08
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Date Posted:
3/24 4:11pm
Subject:
RE: Machining Lightsaber Props
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Haha, nunchuck lightsabers, just imagine hitting someone with those :P
What is the mill used for anyways? I know most of the work is done on the lathe, but what does the mill do?
Anyways I talked to Evil Henchman about some lightsaber Hilts, this topic can sink into darkness.
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TheMuffin
Registered:
Nov '05
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Date Posted:
3/26 7:57am
Subject:
RE: Machining Lightsaber Props
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Hmm, saw this too late. I'd be willing to throw out a quote on machining your designs if you'd like. Not trying to undercut Henchman or anything. Just figured I'd give you another option.
-----signature-----
I am currently taking custom lightsaber orders.
Keep it simple and contact me for details.
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Smiling-Otter
Registered:
Mar '01
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Date Posted:
3/26 9:08am
Subject:
RE: Machining Lightsaber Props
- Date Edited:
3/26 9:10am (1 edits total)
Edited By:
Smiling-Otter
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Think of a mill as sort of deluxe drill press. With a mill, the piece to be machined can be precisely moved along an x- or y-axis. On this saber http://www.randomsabers.com/saber.php?name=Maleficent the cutouts on the emitter and the v-shaped grooves on the activation box have been created using a mill. And very likely the holes for the LEDs and covertec wheel were drilled with the same machine.
On Hapajedi's saber-chucks, the long grooves running the length of the hilts were done with a mill.
Hope that helps.
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TaunTaunHerder
Registered:
Oct '07
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Date Posted:
3/26 4:20pm
Subject:
RE: Machining Lightsaber Props
- Date Edited:
3/26 4:23pm (1 edits total)
Edited By:
TaunTaunHerder
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Use your lathe skills to make the hilt out of hardwood, and then just embellish it.
Please make your lightsaber duel unique and see to it that it doesn't take place in a forest, a parking garage, or a factory.
Especially not in tortilla factory.
Ask Dorkman Scott about that one.
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FlamingRain
Registered:
Mar '08
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Date Posted:
3/26 8:55pm
Subject:
RE: Machining Lightsaber Props
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It'll probably end up being in my house.
Muffin, if you want to send me quotes, I haven't ordered anything from Henchman yet.
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TheMuffin
Registered:
Nov '05
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Date Posted:
3/29 7:39pm
Subject:
RE: Machining Lightsaber Props
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Didn't get an email saying I had a PM. And now you have a PM FlamingRain.
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I am currently taking custom lightsaber orders.
Keep it simple and contact me for details.
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