Designing My Own Hilt and Building It

[petary791]

Well I love this hilt. I can't even believe I found it, I was just walking through Kay-bee Toy's looking for a lightsaber, and I saw this Orange one and i'm like, "Whoah, that things original, i'm getting it!" So I got it, and i'm using it, and it's an extremely comfortable hilt, it looks cool too. The only bad thing is that the button to turn the light on turns off REALL REALLY easily, but enough of me telling the story how I got this...

Basically, I want to turn this into a PVC or EL-type lightsaber. Here's the picture of the hilt, and I'm wondering, how can I go about making this into a nice metal saber!? Pics below:






^the back side, it seems like there's a little place to make a belt clip^

EDIT: Alright I have figured out that this looks a lot like Obi Wan/Qui Gon's saber, only the colors are backwards:


Can anyone confirm this?

[Leda EmBorr]

The small pic above is Qui-Gon's saber in the Phantom Menace. Interesting that the plastic one has a red blade. Both Hasbro and Rubies are in the habit of re-using hilt styles and putting assorted colored blades on them for variety.

[Don Solo]

yeah, I got that orange saber too... hasbro pretty much did what you said - use different colors with Qui-Gon type mold.

um, as for how to go metal? ...well, if it's in your budget get the main silver part machined on a lathe so you have all those groves in it, and use a black tube with cutouts for the grip. not sure how to make it a scratchbuilt hardware saber though

[sulla]

at the bottom of this page is a saber that was made from PVC bits like the Qui Gon one you have:
padawansguide.com/lightsabers.shtml

Note, the three hardware sabers on this page sent in by "Andy" are mine.

You could do the exterior pipe in hardware store sink drain pipe. Some pipe cutters, metal sheers, and sandpaper would do it OK. For the inner ridges there is a specific type of black plastic hose that fits within the pipe fairly well. i can look that up for you if you'd like.