Savi's Workshop / Galaxy's Edge Lightsaber Blade Insert

Last crawled date: 4 years, 2 months ago

This is meant to work as an end-cap for a Lightsaber Blade that would fit the chassis sold at Galaxy's Edge / Black Spire Outpost / Savi's Workshop.
I've tested it out and it does fit. The saber seems to like a 1.10" diameter insert, with a 3.20" depth -- the last 0.20" of which is the rectangular plug and pogo pins.
The inner diameter of the sheath is 1" to fit a 1" polycarbonate tubing blade.
Inside the sheath, you can put one of two different files:
a basic round insert, which is ideal if you also need to fit a polycarbonate blade in, or
a 3.1" high shuttle that will occupy the full height of the sheath.
Both of the inserts have space for you to insert three nails or tacks into them. These nails will act as the conductive pads that the pogo pins inside the saber will contact against. You may need to machine the holes a touch larger with a drill bit depending on what nails you have on hand, but remember to hit them with a bit of sandpaper first to remove any non-conductive coating and file down one edge if it overhangs the rectangular hole in the middle.
The shuttle insert has cutouts on the sides so that you can access the platform in the middle -- an Arduino Nano should fit easily on it, and power itself from the GND and VCC pins -- the cutouts should also give you access to solder your wires onto the nails or tacks that you used as contact points!
For more info on the three pogo pins that the saber chassis has, identifying GND VCC and Signal, and the like -- the Dead Bothans Society @ Burbank Makerspace has a great primer here: https://www.deadbothans.com/videos/ ("Galaxy's Edge Custom Blade Build Part 1: Reading Data from the Hilt")
Plans for future revisions:
Changing the external bumps to be metal, for durability. Possibly with these fasteners: https://www.boltdepot.com/Product-Details.aspx?product=14315 joined with https://www.boltdepot.com/Product-Details.aspx?product=6912, with the heads turned down (or put in a drill and filed down) to the proper diameter (0.2" for the machine screw, and 0.3" for the less common screw bolt thing)