Lightsaber Chassis MHSV1 Proffie Big Battery by SgtSpamCan

Last crawled date: 3 years, 3 months ago

Intended to be used as a chassis for an MHSv1 hilt built from parts from TheCustomeSaberShop.com
This will house:
a 28MM 4W Wow bass speaker
a 26650 Unprotected cell
a Proffie board
A battery protection circuit board
This will fit in a standard MHSv1 hilt, 1.25 inch ID, plus a male-to-Male adapter followed by a 4-inch extension tube which also must be 1.25 inch ID. Add whatever blade holder and pommel you like at the top and bottom, respectively.
A 26650 battery is large, nearly double the capacity of a 18650 battery, and very welcome in order to feed power hungry Neopixel blades.
Pieces are glued-up using 5-minute clear 2-part epoxy. Assembly of pieces is in this order:
Speaker Holder (with Speaker Front Ring glued in place to hold Speaker in). use either the ported or non-ported speaker holder depending on the speaker you use.
SpeakerToBatteryCoupler
26650 Battery Holder v20
BatteryEnd Top
BatteryToChassis Adapter
Board
Board End Support
There are matching holes between the "SpeakerToBatteryCoupler" and the "26650 Battery Holder v20" that are 1.75mm diameter. It is intended that you cut off a small piece of 1.75mm filament and use that in the holes on each end as registration guides to help align those two parts for glue-up, as there was no opportunity otherwise to print registration guides on the parts without making a mess of those two surfaces.
All parts were designed to be printed with NO Additional supports from your slicer.
Some parts include support, such as 26650 Battery Holder v20, and BatteryEnd Top, to support the area where the battery lug will slide into place. use an Exacto to cut out the thin support piece. Pictures to follow.
The Speaker Holder is meant to go with this part, however other 28mm speakers should work as well:https://www.thecustomsabershop.com/4W-28mm-WOWSpeaker-P1511.aspx
I removed the 2nd foam ring from the speaker, keeping only the first one, it was unnecessary.
The battery holder is intended to be used with battery lugs readily available from www.Digi-Key.com:
PART: 36-1107-1-ND
MFG : Keystone Electronics / 1107-1
DESC: BATT CONTACT SPRING MULT SLD LUG
Which at the time of this writing costs $1.70 for 10 battery lugs.
Here's a YouTube video of my completed lightsaber based on this chassis:https://www.youtube.com/watch?v=Vib1W9jDCtg&t=11s
*More to come including some assembly pictures