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…
I grabbed a short chunk of 8/4 walnut off my scrap pile and ripped it down square.
I came down about 2-1/2″ from the end, then marked and drilled a 5/8″ hole for the cross-piece.
I marked the centers of the ends and drilled a 7/8″ hole in the blade end with a forstner bit.
Since this handle is a lot longer, I used a speed bit to drill a bit deeper, through the first hole.
I repeated the process on the opposite side with 1″ bits.
With the holes bored all the way through, I set the handle into my homemade bushings and roughed out the handle shape.
I then shaped and sanded the rest of the handle.
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.
I re-drilled the cross-piece hole, through the tube.
Assuming the light won’t make a deliberate right hand turn into the cross-pieces, I cut the tube 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.
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.
I reamed out the end of the tube to make room for inserting the cap. The cap keeps you from getting blinded in battle…
The last step is to add a bit of tape to create a friction fit on the light.
After pressing the light into place, I fired it up.
The light didn’t extend as far along the cross pieces as I would have liked, but Adam seemed to like it.
Two of my sons tested it out and gave their approval, so it is good enough for now.