For the padawan saber that I made I have to give credit to Project Naboo
which provided a very detailed parts list and instruction guide so it was
great for a beginner like me.
My husband Talon's custom saber was completely designed by him and is made
from relatively inexpensive materials and it looks great. He started with an
11" length of 1" white pvc pipe (the thicker pipe not the really thin
stuff). He then used the dremel to do the cutaways on the top side and
bottom. After the cuts were done he sanded down all the edges so it had a
nice rounded look. The black grip was done by finding a black pvc pipe that
would fit into the 1" white pvc snuggly. He then took a hack saw and made
cuts aprox. every 1/4" and only half way through the pipe to match the grip
cutaway on the white pipe. Then he used an exacto knife to remove every
other cut section. Then more sanding. He then took a third pipe black pipe
that he found in the plumbing section and fit it snuggly into the grooved
black pipe. He decided to add a small dowel rod to the black grip pipe
assembly for added weight but that would be optional. The black grip
assembly is then slid into the white pvc pipe. The emitter is a strange
little piece that he found in Lowe's plumbing section. It kind of looks like
a piece of a faucet. The end cap is a silver threaded ring that was found.
The activator button came off of an ink pen. The recharge port was a plug in
port thing off of an old stereo that he filed down with the dremel. The
blade adjust knob was a decorative knob found around the house and the belt
clip is a brass-like picture hanger that we sanded all of the finish off<
until it looked like nice worn belt clip. That's basically it. Total cost
. less than $10 and it looks great.
I hope my description isn't completely mind-numbing. Anyway, we had a great
time making these sabers and got some great ideas for other sabers. We are
working on one together now which is a total custom designed by the combined
effort of our creative minds...... Look out! ;-)