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Basic Assembly

Let's move on to putting your saber together.
Tools you will need:
Drill or Drill Press (preferred)
8-32 Tap set
Screwdriver
Cutter
Acetone (preferred) or Nail polish remover

Here are all the parts you need:
Chrome pipe
Copper reducer
Washer
Chrome cap
PEX pipe
Chair tip
Screws
Socket head screws

Using a piece of tape attach the washer to the bottom of the reducer. This is only so the washer will align right when you insert it into the chrome pipe, there will be no stress on this tape.

Insert the reducer into the pipe as shown:

This is what it should look like:

Replace the ring:

The chrome cap goes on to the bottom of the pipe:

Like so:

It is not required, but you could use some sort of reflective material in the tip. A polished nickel will do.

This is where you put it:

Push the tip onto the end of the PEX pipe:

It should look like this:

Cut the PEX pipe to the length of a blade you are comfortable with. Clean the writing with acetone or nail polish remover:

Holding the reducer tight in place, drill a hole through as shown:

Tap this hole with the tap set:

Insert a screw and tighten it. Then drill another hole right bellow the first one. Also, drill 2 more holes aligned with the first one, but at 120 degrees from each other around the circumference of the pipe:

Tap these holes and insert the screws. Also, drill and tap a hole into the thin section of the reducer and insert one of the socket head screws:

This is how it looks from the opposite side:

You can use the small chrome cap to cover the emitter hole:

Or loosen the socket head screw, insert the blade and tighten the socket head screw to hold it in place:

This is your basic saber.
Now let's consider what you have here:
A hilt with a removable blade
A nice blade holder/emitter
A place where you can install your LED (on the washer)
A duel-able blade that doubles as a light diffuser

Alright, so it's not polycarbonate, but it will withstand pretty serious blows without damage and it's quite light.
From here, your imagination can take this anywhere. You can decorate the hilt with all sorts of accents, you can add electronics for light and sound, switches, D-rings and knobs, grips and anything else you can think of. Good luck!

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Basic Assembly
Let's move on to putting your saber together. Tools you will need: Drill or Drill Press (preferred) 8-32 Tap set Screwdriver Cutter Acetone (preferred) or Nail polish remover

Here are all the parts you need: Chrome pipe Copper reducer Washer Chrome cap PEX pipe Chair tip Screws Socket head screws

Using a piece of tape attach the washer to the bottom of the reducer. This is only so the washer will align right when you insert it into the chrome pipe, there will be no stress on this tape.

Insert the reducer into the pipe as shown:

This is what it should look like:

Replace the ring:

The chrome cap goes on to the bottom of the pipe:

Like so:

It is not required, but you could use some sort of reflective material in the tip. A polished nickel will do.

This is where you put it:

Push the tip onto the end of the PEX pipe:

It should look like this:

Cut the PEX pipe to the length of a blade you are comfortable with. Clean the writing with acetone or nail polish remover:

Holding the reducer tight in place, drill a hole through as shown:

Tap this hole with the tap set:

Insert a screw and tighten it. Then drill another hole right bellow the first one. Also, drill 2 more holes aligned with the first one, but at 120 degrees from each other around the circumference of the pipe:

Tap these holes and insert the screws. Also, drill and tap a hole into the thin section of the reducer and insert one of the socket head screws:

This is how it looks from the opposite side:

You can use the small chrome cap to cover the emitter hole:

Or loosen the socket head screw, insert the blade and tighten the socket head screw to hold it in place:

This is your basic saber. Now let's consider what you have here: A hilt with a removable blade A nice blade holder/emitter A place where you can install your LED (on the washer) A duel-able blade that doubles as a light diffuser Alright, so it's not polycarbonate, but it will withstand pretty serious blows without damage and it's quite light. From here, your imagination can take this anywhere. You can decorate the hilt with all sorts of accents, you can add electronics for light and sound, switches, D-rings and knobs, grips and anything else you can think of. Good luck!