New force Awakens Lightsaber experiment…
There are three types of people in this world: Star Wars fans, Star Wars geeks, and Star Wars indifferent… My three boys and I fall somewhere in between the first two. I had to cut out a couple more handles to make some more lightsabers, so I thought I would get a bit creative and try to make a quick version of the new Sith lightsaber from the new Star Wars “The Force Awakens” trailer. I spent maybe an hour on it, so don’t expect any miracles…
Ripping down a piece of 8/4 walnut
I grabbed a short chunk of 8/4 walnut off my scrap pile and ripped it down square.
Location the cross-piece
I came down about 2-1/2″ from the end, then marked and drilled a 5/8″ hole for the cross-piece.
Drilling the cross-piece hole
Finding my center
I marked the centers of the ends and drilled a 7/8″ hole in the blade end with a forstner bit.
Drilling 7/8″ hole
Since this handle is a lot longer, I used a speed bit to drill a bit deeper, through the first hole.
Follow up with the longer speed bit
Flip and drill the 1″ hole on the opposite end
I repeated the process on the opposite side with 1″ bits.
Follow up with the speed-bit again
Roughing out the handle
With the holes bored all the way through, I set the handle into my homemade bushings and roughed out the handle shape.
Shaping the handle
I then shaped and sanded the rest of the handle.
Sanding the handle
Add a little tape for a friction fit
I cut a 3′ long piece of 3/4″ PEX tubing and added a bit of tape to one end for a good friction fit, then pressed it into place.
Set tube below the cross-piece hole
I re-drilled the cross-piece hole, through the tube.
Re-drill hole through tube
Assuming the light won’t make a deliberate right hand turn into the cross-pieces, I cut the tube at an angle.
Cut the two cross-pieces at an angle
I pressed the angled end into the hole, just past the inner tube. My hope is that light will refract a bit into the cross-pieces by hitting the bit that protrudes into the center.
Locate depth
Mark depth
I set and marked each one, then applied CA glue to the holes and pressed the pieces back in. There is not much wood to support these arms. They may not take much of a hit when the kids are battling. I think if I revise this design in the future, I will glue on additional wood side pieces to give extra support.
Add a little super glue and insert cross-pieces
Hand tube end ream with drill bit
I reamed out the end of the tube to make room for inserting the cap. The cap keeps you from getting blinded in battle…
Set end cap
Add tape to flash light and press in place
The last step is to add a bit of tape to create a friction fit on the light.
New Sith light saber complete
After pressing the light into place, I fired it up.
Cross-pieces are not as bright as I would like
The light didn’t extend as far along the cross pieces as I would have liked, but Adam seemed to like it.
Dark-side Adam
Two of my sons tested it out and gave their approval, so it is good enough for now.
Light-side Adam
Midnight Woodworking 