One Day Lightsaber
Introduction: One Day Lightsaber
This instructable will demonstrate how to build a quality Lightsaber in one day. Normally it takes many weeks and countless hours when I build a Lightsaber. This version will be less sophisticated yet still be a wearable and displayable energy weapon. I always recommend designing your own Lightsaber and never copying the original. The originals have been copied and reproduced to death. Plus, I love having something no one else has. This version will be machined on a metal lathe and drill press only. I use 6061 aluminum because its easy to find and it anodizes well.
Any step of this instructable can be modified depending on what you have available, materials, tools, etc. After a final polishing and assembly, all aluminum parts will be anodized black at a later date.
This Lightsaber project requires only the very basics of lathe machining. All main fasteners are 1/4-28 set screws which provide sufficient strength for assembling. Complete artistic freedom should be applied to any and all steps so you end up with a Lightsaber that will truly be unique...young <PERSON>.
Supplies
Metal Lathe
Drill Press
Vise
Aluminum stock in various diameters
Brass stock in various diameters
Hacksaw or bandsaw
Selection of drillbits
Miscellaneous fasteners and set screws
Step 1: Front Emitter
The front emitter is machined from 1.5 inch diameter aluminum about 2.25 inches long. Use a center drill before drilling a 1/2 hole about 1 inch deep. Machine a pleasing taper. Then with a cut-off blade, machine evenly spaced slots about 3/16 inch deep. Now drill a 7/32 inch hole deep enough to clear through the entire piece. Tap 1/4-28 threads for attaching an emitter cap. Sand and polish till smooth. Use a cut-off blade or hacksaw to cut the part away. Machine the other side flat. Done!
The last photo has rubber O rings in the slots to help demonstrate the look when the finished Lightsaber is anodized black and some areas remachined to reveal silver against black.
Step 2: Emitter Cap
The emitter cap is machined from 1-1/8 inch brass stock. 582
A 3/8 inch diameter hole is drilled about 3/4 inches deep. Now drill a 1/4 inch through hole for attaching to the emitter. Sand and polish for a smooth look and feel.
Step 3: Emitter Shaft
The emitter shaft is machined from 1 inch aluminum rod about 1-3/4 inches long. Drill both ends with a 7/32 bit and tap 1/4-28 threads about 3/8 inch deep. Machine wide at one end and 3/4 inch at the other. Sand and polish smooth.
Step 4: Front Emitter Assembly
Assemble the front sections with 1/4-28 set screws and proceed to step 5.
Step 5: Center Barrel
The center barrel section is machined from 1-3/4 inch aluminum stock. Drill a 7/32 inch center hole on each end and tap 1/4-28 threads 1/2 inch deep. Machine each end flat. Carefully layout 12 drill points for 3/16 inch holes. Center punch for each hole and drill at least 1/4 inch deep. Now drill 3/32 inch holes inside of the 3/16 inch holes about a 1/4 inch deeper. Carefully tap 4-40 threads into these smaller holes. Be mindful young Padawans as these small taps can break easily! Lubricate as needed.
Step 6: Brass Heat Disapators
Machine heat disapators from 3/16 inch brass stock. Make each one 3/4 inch long and center drill (very important for these small parts). Now drill a 3/32 inch hole and tap 4-40 threads about 1/8 inch deep and insert a set screw. Repeat 11 more times for a total of 12 parts.
This step took over an hour and was the most tedious of the whole project. Be careful of those 4-40 taps as they can break easily. Lubricate as needed!
Step 7: Attaching Heat Disapators
After the barrel has been tapped for 4-40 threads, screw in all 12 disapators and machine the entire assembly. Now unscrew each disapator and machine a slight chamfer on the machined edge and reinsert. This assembly is finished!
Step 8: Attaching Barrel Assembly
With a 1/4-28 set screw, attach the barrel assembly to the emitter shaft and proceed to step 9.
Step 9: Machining Brass Coupling
A coupling is machined from 2 inch diameter brass stock. Drill a 7/32 inch hole the full length of the part and tap for 1/4-28 threads. 819