Well I really needed to make one of these. Not about to spend $300 to $$$ for the parts on line, I found the following in my shop:
New tool bit for the lathe:
Lathe Tool Bit used for many operations on my Lightsaber
Universal Insert Lathe Tool bit Holder....Get any angle on that tool bit.
Adam Savage makes a light Saber (found the source drawing on line) See next post for link
I designed mine so I could bore it out and install the electronic parts for sound and light instead of just making it in one
piece for a prop replica. Dimensions should be quite accurate overall.
Ordered a sound board and some switches on the bay and made a set of Cad prints to build from based on online pics and dwgs. (Just a bit over dimensioned!)
Also needed was a 3 watt led. They are supplied on a large aluminum heat sink but I modified it by removing the large heat sink and adding
a (1/4" x 1/4") brass rod and soldered it to the base of the led in place of the aluminum heat sink. Heat shrink to insulate it. My version uses
a 1/2" polycarbonate solid tube for the saber. Not the brightest method but quite simple and direct.
Source for sound board:
I used a 3 cell AAA flashlight battery holder for the power. (used some E6000 glue to insulate any electrical connections.
One other note not on the prints. I used a mylar sleve to insulate the parts from the shank and also heat shrinked a tube over the board.
So here are the pictures and prints in jpeg format: