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This thread is dedicated to my last lightsaber build. I will show the entire process from beginning to end. I hope you guys enjoy it!
I used pre-machined parts for the hilt, but I added custom accent elements to make it unique.
I used pre-machined parts for the hilt, but I added custom accent elements to make it unique.
07:24 PM - May 03, 2023
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This was the beginning stage of the crystal chamber. I designed it in Shapr3D and then 3D printed it using specialty PLA. This lightsaber build allows me to open it up to reveal the internal components.
07:25 PM - May 03, 2023
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I soldered JST-PH 2.0 connectors to the soundboard to ensure the electronics and LED strips worked correctly. I used the Golden Harvest v3 soundboard; it is the main component of the lightsaber.
07:25 PM - May 03, 2023
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I decided to go with a slightly different hilt design.
07:31 PM - May 03, 2023
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I made changes to the crystal chamber, and I 3D printed the parts with a cheap filament to see how everything fit.
07:36 PM - May 03, 2023
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I started adding brass accent parts to the lightsaber.
07:39 PM - May 03, 2023
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I ended up making changes to the hilt and pommel. I also added more brass accent pieces.
07:42 PM - May 03, 2023
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I made a synthetic Kyber crystal. First, I made a mold using a genuine crystal and a silicone mold kit. Then I filled the mold with clear resin and added a Neopixel at the base of the Kyber crystal. Now the Kyber crystal will light up when the lightsaber is on.
07:44 PM - May 03, 2023
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This is the Kyber crystal seated in the prototype crystal chamber. The crystal chamber was 3D printed with a cheap matte filament for fit...etc. When all of the parts are designed and fit as expected, I will use metal-infused filaments for the internal chassis.
07:51 PM - May 03, 2023
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This is how the Kyber crystal will look inside of the lightsaber hilt.
07:52 PM - May 03, 2023
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I finished designing the first half of the lightsaber chassis. Everything fits perfectly inside of the hilt and works as expected. Now I can 3D print the top half parts in the more expensive metal-infused filament and start working on the bottom half of the chassis.
07:57 PM - May 03, 2023
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I printed the parts with filaments filled with metal. This particular filament is filled with iron, and it's actually magnetic. Once it is sanded, it can oxidize and rust. I used filaments filled with bronze and copper.
08:00 PM - May 03, 2023
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The first photo is a standard PLA part, and the second photo is an iron-filled PLA part. Part A is 16 grams and part B is 23 grams.
08:03 PM - May 03, 2023
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The finished design of the chassis. Now it is time to print the rest of the parts and put it all together.
08:22 PM - May 03, 2023
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The internal 3D parts are ready for post-processing. The metal-filled 3D printed parts still look like plastic until they are sanded...etc. But when everything is done, they will look like metal.
08:28 PM - May 03, 2023
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It's starting to look metallic, but a lot more post-processing is required.
08:28 PM - May 03, 2023
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Since I used metal-filled PLA, the parts can oxidize and rust. I used a 50/50 solution of vinegar and hydrogen peroxide mixture to accelerate the process.
08:31 PM - May 03, 2023
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It took less than a day for the parts to look old and rusted.
08:32 PM - May 03, 2023
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I sanded the parts again, removing some of the rust...etc. Nice subtle patina.
08:34 PM - May 03, 2023
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I used a pure brass wire brush to expose the metal in the filament, but some of the brass transferred to the part for a cool effect. I then used a tiny amount of gold leaf glue and metallic powders to make the part look realistic. A tiny amount of the powder goes a long way.
08:37 PM - May 03, 2023
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First coat of clear coat.
Note: I use double-sided tape to hold the part while spraying on the clear coat.
Note: I use double-sided tape to hold the part while spraying on the clear coat.
08:38 PM - May 03, 2023
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It is time to start assembling the inner components of the lightsaber.
08:41 PM - May 03, 2023
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Some parts were glued and clamped. I used Gorilla Glue because it doesn't dry quickly and is easy to clean up. The problem with Gorilla Glue is it expands, so only a little is needed.
08:45 PM - May 03, 2023
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I used 3D-printed parts combined with genuine metal parts for a more realistic appearance.
08:49 PM - May 03, 2023
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The bottom and middle sections are completed.
08:50 PM - May 03, 2023
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Assembly of the internal chassis is completed, and now it is time to install the soundboard and wire up everything.
11:33 AM - May 04, 2023
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The emitter is soldered and ready to be installed into the internal chassis.
11:35 AM - May 04, 2023
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The first test went well. Now it is time to add accent lights.
11:40 AM - May 04, 2023
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The steps to putting the internal chassis into the hilt.
11:46 AM - May 04, 2023
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You can activate the lightsaber with gesture controls. Here I used a wrist twist.
11:49 AM - May 04, 2023
In response to Christopher Bouzy.
Finally the puzzle piece I needed to complete the picture of you. The code part had me distracted from the gifted part.
06:37 PM - Apr 23, 2024
In response to Christopher Bouzy.
Dude...you are the most epic philanthropist I believe I have ever been witness too!!!!! I want you to know that makers hold a very special place in my heart and it makes mine overjoyed to know that you are in a community that I am lucky enough to be part of!! This is so cool!!!
12:42 PM - Dec 02, 2023
In response to Christopher Bouzy.
As a mere Spoutawan learner, this is most helpful! 😎
05:24 PM - Aug 27, 2023
In response to Christopher Bouzy.
How I missed this May thread I'll never know!
Your light saber is an astounding work of art!
You are a high tech artiste. 😁
Can hardly wait for your next version. 😜
Your light saber is an astounding work of art!
You are a high tech artiste. 😁
Can hardly wait for your next version. 😜
06:27 PM - Aug 09, 2023
In response to Christopher Bouzy.
Not bad at all. And this is coming from the TCSS moderator.
11:08 AM - May 05, 2023
In response to Christopher Bouzy.
That's freaking cool as h3ll!! I loved the whole thread. Also what a dope 3d printer.
08:47 AM - May 05, 2023
In response to Christopher Bouzy.
Spectacular journey! Thrilled with the final results.
☄️#MayThe4thBeWithYou
☄️#MayThe4thBeWithYou
01:55 AM - May 05, 2023
In response to Christopher Bouzy.
That is just gorgeous Chris. How many hours did it take to make? What did your little one think of it? Thank you so much for sharing all this with us. 😍
06:17 PM - May 04, 2023
In response to Gin Perdide.
It took months, but I wasn't working on it full-time. Liam LOVED it!
01:39 PM - May 05, 2023
In response to Christopher Bouzy.
Ok, that’s next level geeking out und I’m absolutely floored ! And an epic length thread 🧵 on top …you, Sir, have clearly too much time on your hand. May the force be with you.
04:17 PM - May 04, 2023
In response to Christopher Bouzy.
Why do I feel like you got the threads up just so you could spout the cool ass lightsaber build?
That is the best reason I can think of for threads too.👍
That is the best reason I can think of for threads too.👍
02:25 PM - May 04, 2023
In response to Christopher Bouzy.
You, sir, are a man of many talents. This is very impressive. May the 4th be with you. Always.
12:42 PM - May 04, 2023
(Edited)
In response to Christopher Bouzy.
The force is strong in you. #maythe4thbewithyou
12:02 PM - May 04, 2023
In response to Christopher Bouzy.
Just get your crystal attuned to The Force and you're ready for your final steps to Knighthood.
09:49 AM - May 04, 2023
In response to Steve D K.
Isn't he supposed to go to the cavern the Kibbur Cyrstals and one of them will choose him for his saber?
12:00 PM - May 04, 2023
In response to Christopher Bouzy.
So, that thing on my kitchen ceiling is not a light sabre? :(
06:49 AM - May 04, 2023
In response to Christopher Bouzy.
I can't think of a better example of how to thread than this. May the fourth be with you @cbouzy 👏👏
06:30 AM - May 04, 2023
In response to Christopher Bouzy.
Oh for fucks sake Bouzy. I gotta scroll through 30 spouts to see the result?
01:44 AM - May 04, 2023
In response to Minnie the Pooh.
What result?
Mr. B. mentioned a threading bug that doesn't allow the rest of the spouts to display.
#ThisIsNotOver #GrabSomeSnacks
Mr. B. mentioned a threading bug that doesn't allow the rest of the spouts to display.
#ThisIsNotOver #GrabSomeSnacks
06:28 AM - May 04, 2023
In response to Christopher Bouzy.
An epic thread (cascade) to celebrate the #firstdayofthreads . (I still think it should be cascade...)
11:28 PM - May 03, 2023
In response to Christopher Bouzy.
Oh yay! I was hoping you’d post about your amazing project.
11:20 PM - May 03, 2023
