Custom-Built Lightsaber II

Custom designed and built lightsaber machined out of aluminum, anodized aluminum, and brass using lathe and mill. 

media:
aluminum, anodized aluminum, stainless steel tubing, rubber sheeting, hardware parts 

Final completed product

Final completed product

Final completed product

Detail on burnt saber cup

Hanging lightsaber before burning tip with blow torch

Concept CAD

Concept CAD

Testing with color schemes using 3D rendering (FluidRay RT)

From concept to reality

Testing fit after anodization

Aluminum body anodized black

Freshly anodized aluminum

Anodizing process. Part subject to constant current in concentrated sulfuric acid to form oxide layer and then subsequently dyed black

Freshly milled slots in brass shield

Milling brass shield in progress

Detail on shield and cup

Pre-milled brass shield. Testing for fit

Pre-milled brass shield

Testing tolerance of bore in brass shield part

Machining body and saber cup in progress

Machining body in progress

Original concept drawing

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