Custom Curved Lightsaber #4 by jasonramey

Last crawled date: 3 years ago

I wanted to design and print a curved lightsaber handle, and this is the end result. It's about 11 3/4" long, and looks pretty elegant (in my opinion). It only takes 10-15 minutes to assemble.
For assembly, you'll need:
2 or 3 tubes of super glue (you should be buying super glue in bulk at this point)
2 button tops and springs of the push button here
the belt clip assembly here (optional)
Print one of each part except the following:
2x beam70
2x upper_ring
3x upper_spacer
2x handle_middle_half
2x middle_slat
2x lower_ring_2
3x lower_spacer
AssemblyEmitter assembly: Glue the emitter_tip inside the top of the emitter. Glue the end of a 70mm beam (beam70) in the bottom of the emitter. With upper_spacer and upper_ring, alternate spacer-ring-spacer-ring-spacer onto the beam. The gap on each ring/spacer should face the smaller of the two prongs on the emitter. button_ring goes on last and fills in the gap behind the rings/spacers and butts up underneath the emitter piece.
Glue emitter_shadow inside the emitter_tip. emitter_button_cap goes in the recess on emitter_button, and that goes in the side of the emitter. For the buttons on the back of the button ring, follow the instructions for the push button linked above.
Middle section: Take note of the groove on the side of the handle_middle_half pieces. The side where the groove is open is where the two halves will meet. Use the 60mm beam (beam60) and glue the two handle pieces together so they form a circular curve. Then glue the two middle_slat pieces in those grooves.
Pommel assembly: Starting with the pommel, glue the end of a 70mm beam (beam70) on the underside in the square hole. Using lower_spacer and lower_ring_2, alternate spacer-ring-spacer-ring-spacer onto the beam and keep the gaps on the side of those pieces lined up. lower_ring_1 then goes on with the prongs filling in the gaps on the rings/spacers.
The pommel_vent_shadow pieces will go in the slots on the end of the pommel. Glue the two pommel_button pieces in the circular holes on the pommel assembly. Alternately, you can just use one button and the belt clip knob from the link above.
Final assembly: Insert the beam of the emitter section into the middle section so the longer prong is pointing toward the "inside" of the circular arc of the handle and the two buttons will line up with the spine. The pommel obviously goes on the other side (keep in mind which side of the pommel has the belt clip knob if you've used one).
Use the pictures provided if you have questions. After letting the super glue cure, let your nerd flag fly! May this lightsaber be a fine addition to your collection!