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Preparation
Washers
Take 10 of the polywashers and prepare them for painting. Use a sharp knife and some
sandpaper to smooth out any burrs or flash. You may want to hit them with layer of
primer, though roughing up the surface is usually all you need. Now paint 5 polywashers
silver (or chrome) and paint the other 5 black . Most spray paints work well, though I
do recommend something specifically designed for plastics such as model paint. The
third time I made one of these, I actually used standard model paint applied with a brush
and found it worked very well. It will be a while before you actually use these washers,
but at least now they will be ready when you do need them. Give the paint plenty of time
to dry, several days if you can.
Tubes
This step is optional, but if done properly can make a significant difference in the over all
appearance of your saber. What you want to do is give those plumbing tubes a
machined look. Using some medium to fine sandpaper lightly sand the tubes, moving
radially around the tube. This will give the tube a flatter look, similar to aluminum or
brushed steel. Don't get carried away sanding, though, because the plating on these tubes
is thin and you don't want to wear it completely off.
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Cutting the Tubes
The Inner Tube
Okay, it's time to start making some cuts, but first let's talk about the measurements I'm
going to use. Basically I took my finished saber and parts, put them next to a ruler and
then recorded the numbers. When I was actually making the saber I just cut where I
thought it looked best. This design is very flexible. The numbers I'll use will work, but if
you think a section is too short or too long, or you want a button closer to the grip.. then
do it. That's what I did. Take your 1.25" extension tube and cut off about one inch of
the flared end . The new overall length of the tube should be about 10.50".
The Emitter
Shroud Substructure
Take three unpainted polywashers . Slide them onto the 1.25" extension tube, moving
all the way down until the flaring section stops them . Now take one of the
polywashers that you painted silver and slide it down the tube to the other washers ,
making sure that the widest end of the washer is toward the flared section of the tube. The
emitter shoud will now slide over the three unpainted polywashers, but we'll save that
step for last since it will be easier to work with the saber without the tube section on for
now.
Emitter Vents
Take the five polywashers that you painted black. Slide them down the until the meet the
silver polywasher . I had all of my black washers aligned so that the widest ends were
toward the flared end of the tube, but this is a great place to experiment with what you
like best. Place the washers the opposite way, or alternate them, or whatever. You know
the saber actually looks really cool if you use black washers where I call for silver and
silver where I call for black, or washers of all one color (either color).
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The Grip
Preparing the Grips
Okay, the first thing you need to do is get an idea of how long the grip section of the tube
shall be. By this I mean the section of the 1.25" tube between the control collar and the
pommel. To know that, you need to figure out how much of the 1.25" tube the pommel
itself will take up. To know how much room the pommel with take up, simply add the
length of your pommel tube section to the length to two of you polywashers. It will
probably be somewhere between 1.25" and 2.00". Once you know that you can figure out
how much space you have for the actual grips. I ended up with 5-3/8" for mine. Take
your section length and subract abount 1.00" for the length of your individual grips. This
will give a 0.50" clearance on either side of the grips. Now take you wiper refills .
You'll see that they consist of a rubber blade set into a plastic track. Cut off one of the
tips and slip out the rubber blade. It's the plastic track that you'll be using. Next cut
yourself six even sections of grip using the measurement you determined above . It is
important to the look of the saber that you make all the grips the same length. To make it
easier I screwed some wood screws as stops into a wooden block . With this and my
Dremel, I made short work of creating equal segments.
The Pommel
Emitter Insert
This is one of those areas that you can really get creative in. I decided that I would take a
very, very easy and inexpensive option on mine. Take the Fujifilm Film canister . Cut
off a secton of the end with the cap. Drill out the center portion of the cap (or don't..use
your imagination), and paint the cap as you would like . Glue the canister section into
the remaining flared portion of the extension tube .