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Lightsaber Project - Outer Tube
This is a closeup of the detail on the upper part of the saber. I used the template
from the website above, and traced the shapes onto the pipe. Cutting the shapes with
a dremel was slow and steady work. I slipped a few times and now a have a few dremel
"skid marks" on the finished body.. oops. Take your time and be careful!
I wish I had taken a picture of the original part before I started the dremel work.. (sorry)
This started as a piece of 12"x 1.5" flanged tailpiece sink tubing. I cut the end of
right before the flange, so from end to the top of the arch is about 10 1/2".
I got most of my ideas and cutting templates from
this website,
and I'm going to make up the rest as I go.
I must admit that making this part was quite hard. I started with a piece of craft
sheet aluminum purchased at the local hobby store. I then used a dremel cutting disc
to cut out the elongated shape. This took a LONG time to do and to keep the edges straight.
Note: I suggest making some small notches on either sides of the
tabs before bending them, trust me, it makes the bending easier. I then bent in the 4 tabs, and bent the main part around a
piece of PVC piping to make the arc shape. This piece was hard to make, and I was VERY lucky
to have gotten it right the first time around.
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