Are you planning on having the end of the stick light up? (I'm assuming that would be the whole point ) I would go about building the lightsaber first. I'd make a 1.25" LED saber, then get a solid polycarbonate rod and have someone machine it down a bit so it tapers. Fit that to the lightsaber, once you've built it. A rod like this is what I'd use: [image=http://www.usplastic.com/images/products/sheet/43254p.jpg] This is from usplastic.com Don't use acrylic, that plastic type would be too brittle, if you were actually planning to use it. If you're just going to show it, then it would be ok. I think it's a cool idea, if you can do it. I wouldn't think it would be too hard, once you learn more about lightsabers, if you don't know much yet. You can get lightsaber building ideas and tutorials [link=http://www.thecustomsabershop.com/forum/index.php]here[/link], if you didn't know by reading enough of this thread.