Hello everyone!) A lightsaber is an integral attribute of the Star Wars films, a cult craft that every person who calls himself a Star Wars fan and a follower of Obi-Wan Kenobi should have...
For years I wanted to get my hands on the "original" lightsaber. However, the industrial designs that were presented on the market did not meet the requirements I had stated (I didn’t even want to take on a plastic likeness of the majestic artifact). So I had an idea do their hands a sword that would suit my desires and look unsurpassed.
In the article we will consider in detail how and from what parts it will be possible to make this homemade.
Some of the parts used can be replaced with plastic pipes, but then the parts will lose some of their strength and the effect of realism will be reduced.
This sword glows and changes colors (no light or sound effects). With the right skill set, you can easily add additional features to this product.
I want to immediately dot all the “E”s, I am not a plumber or a seller of plumbing products, so the names below may be incorrect.
Using glue, we attach the straight coupling, the nut from the selector switch and the washer together.
Since the power source is a 9-volt battery, it is necessary to find a way to secure and hide it in the hilt of the sword.
Unfortunately, the inch pipe is too narrow to fit, but the inch coupling fits just right. To prevent the battery from falling out and not “damage” the battery itself, we secure the nut and washer (after gluing them with glue) to one end of the coupling.
Once the glue has dried, check the quality of the seam and, if necessary, glue everything again.
We disassemble the split coupling and select the part that we like best.
We twist together: part of the split coupling, the bend and the straight coupling.
Let's take an inch pipe and cut a piece of any length (the main thing is that you feel comfortable) taking into account the fact that you will need to attach the guard and pommel to it.
Let's take a polycarbonate tube and install it in the guard. Leave space in the guard for switches.
The copper wire will not only help securely secure the blade, but will also make the sword stand out thanks to its own unique design.
After installing the blade tube, we drill through holes of the same diameter as the copper wire. Let's cut it into small pieces and then mount it as shown in the photo. Then use super glue to securely fix it.
First, decide where you want to place the switch or switches. Since I wanted the sword to glow in different colors, I had to install two different switches. One is power, the second is color switching.
Let's install switches at the top of the guard so that the copper wires protect them in the heat of battle.
I drilled, cut and sharpened the guard, getting two large enough holes to fit the switches.
We don’t secure them yet, otherwise we won’t be able to connect the wires to the LEDs.
Take a strip of LEDs and cut a section about twice as long as the intended length of the lightsaber blade (make sure you cut the strip in the correct place - along the cut line).
The strips should have a 4 color pinout pinout attached to one end (most likely red, green, blue and white).
Let's strip the ends of the wires. We hold the white wire on the positive terminal of the battery, and the remaining wires (individually or all at once) on the negative terminal.
Let's fold the strip of LEDs in half and pass it along the blade. Then we place the wooden dowel in the plastic pipe. The tape will be sandwiched between the pipe and the dowel.
Let's pass the wires through the guard and solder them where necessary. Let's secure the switches.
Finally, we’ll add a diffuser to diffuse the light from the LED strip.
It would be possible to paint the blade with white paint.... but I decided to keep it looking great and just used wax paper.
Roll up a tube of paper of sufficient width and length so that it fills the tube and slides along the inside of the blade around the double-sided LED strip.
It will take a little effort, but in the end you will get great results.
I filled the top of the blade with silicone to seal the plastic tube.
May the force be with you.
If you are a Star Wars fan or have a little boy in the house who dreams of a glowing sword, then you just need to get this thing. There is no need to buy it at all, since this “weapon” can be made independently from parts that are very easy to get. The photo report and instructions that await you below will tell you how to make a lightsaber with your own hands.
We buy these diodes in quantities of 110 pieces.
We solder in parallel (here the solder is divided into 4 parts).
The division into 4 parts is made so that you can connect all 110 diodes to 4 batteries with a power of 3.6V each. 350mA driver.
Since a strip of 110 diodes is divided into 4 parts, then each part (~26 diodes) carries 350mA. 14ma for each diode. Chrome plated steel cylinder with a diameter of 30mm and a length of 250mm. It will hide batteries and wires.
The blade itself is a polycarbonate tube with a diameter of 30mm, a wall thickness of 2.5mm and a length of 1000mm.
A white packaging film and diode strip are placed inside this tube.
The bottom cover is printed on a 3D printer, where the power button will be located.
Back in 1976, the first creation of George Lucas appeared on the screens - the beginning of the Star Wars saga. The author's fantastic idea captured the hearts of people who became ardent fans of the film. Every girl dreamed of being like Princess Leia, and boys imitated the heroic warriors. We invite you to make a Jedi sword with your own hands. It would make a great toy for a little fan or complement the role play of an adult Star Wars fan.
In order to create Jedi swords for children, you need to choose safe materials. The most suitable option is to make a toy weapon from a simple flashlight. It should fit comfortably in the baby's hand. It is better to choose a lighting device that has diodes inside. They are durable and consume minimal energy, so you won't need to change batteries often. Make sure the flashlight produces colored light. If you don’t find one, don’t be upset: you can remove the glass and paint the diode in the desired shade with ordinary nail polish.
The second component of the toy sword is a polycarbonate tube and a small plastic plug. Adjust the length of the blade yourself by trying it on with your child. 60-80 cm will be enough. The cross-section of the pipe should be slightly smaller than that of the flashlight. You will also need hot glue or transparent “Moment” and electrical tape.
Assembling a formidable laser sword is quite simple. First, prepare the blade. Polycarbonate is transparent, and you need a material that will diffuse the rays. To make the tube matte, carefully go over it with sandpaper. Using hot glue, attach the cap to the top of the blade. Remove the glass from the flashlight and fit the tube to the handle. If it does not fit tightly inside, make several turns of electrical tape. Secure the blade with glue to the top of the lantern. All that remains is to check the toy in operation. Your child will jump with happiness! Create Jedi swords for his friends, and they can play against the forces of evil.
Such a weapon, made with your own hands, will cost you little (unlike offers in toy stores, where the price is very steep), and you will spend a minimum of time on its manufacture.
To make a lightsaber you will need:
In addition, you will need hot or instant glue and electrical tape.
Now let's look in more detail at how to make a Jedi sword. First you have to “gut” the flashlight. Carefully remove the insides. See if the inverter fits inside the tube. If yes, then everything is great!
Remember that the cross-section of the tube should be slightly smaller than that of the top of the lantern. Choose the blade size yourself. Sand the ends of the plastic with sandpaper, as it is very easy to cut yourself on them.
The size should be slightly larger than the tube. Use hot glue to secure one end to the cap that will cover the top of the weapon. The tape should be inside the polycarbonate tube. Jedi swords glow evenly along their entire length; cold neon will give you this effect.
To connect the tape to the inverter, you just need to insert the connectors into each other. No soldering or additional manipulations are required, which is very convenient. Check the lighting operation.
To ensure that the sword serves you for a long time, carefully fix the inverter inside the tube using hot glue. This way it will not dangle and hit the walls of the case.
All that remains is to carefully insert the tube into the base of the handle and secure it with glue. The lightsaber is ready! This option is suitable for both role-players and children.
Fans of insidious images also need Jedi swords. After all, the Sith simply switched over and created their own order. Darth Maul wielded dual weapons, which provided an element of surprise in battle. His red lightsaber frightened everyone who came across the dark lord on the way.
As you may have guessed, it will not be difficult to make. You just need to collect two swords with a red neon ribbon. Please note that their blades should be slightly shorter. Connect the flashlight handles together using black electrical tape. Make the winding strong so that the parts do not dangle. You can first fix their bases with “second glue”, and then go over them with black insulating tape.
Now you know how to make a Jedi sword with your own hands. Real fans turn metal hilt parts on lathes.
They use special compounds to treat steel to achieve a realistic effect. Thanks to the assembly process described in the article, you can continue on your journey to making formidable weapons to protect the universe.
So, you have decided to take the last step towards understanding the Force. Do you gravitate towards the Dark or Light side? Keep in mind that followers of the Dark Side are given cookies... Regardless of which side you decide to take, you will need a lightsaber. This article will tell you how to make a lightsaber with your own hands. This project is both an entry-level introduction to electronics, as it requires no prior knowledge, and a fun way to create props for carnivals, cosplay and role-playing games. 
To assemble a lightsaber we will need:
Tools:
- PVC pipe cutter
- Hacksaw
- Drill
- Soldering iron, solder, rosin (you can probably do without soldering, but it will make working with the electronic part much easier and the result more reliable)
Handle materials:
- A piece of PVC pipe with a diameter of 3 cm and a length of 20-30 cm (the length can be any, based on convenience)
- Switch in the form of a button
- Battery compartment for 2-4 AA batteries
Optional:
- Silver paint in a can
- Bike camera
- Small electric motor (to create vibrations in the handle and amazing sound effects when fencing with a laser sword)
Materials for the “light blade”:
- Polycarbonate pipe. Its outer diameter must be at least 2 cm and, at the same time, less than the inner diameter of the “handle”. The length should be about 75 cm, commensurate with the height of the future Jedi
- From 25 to 35 LEDs of the color you need
- Single-core wire with a cross-section of 0.3 mm²
The total length of the sword is: handle length + blade length + 7.5 cm.
Notes on using different materials:
This project uses many different materials. Any tube of suitable length and thickness that is comfortable to grip will be suitable for the handle. One of the Padawans used a scooter handle once and it worked great. We also made sure that tennis racket handles cope well with the task assigned to them. An opaque tube is better for the blade than a clear one because the light needs to be diffused. So a tube made of any light and durable material of the required length will do.
Let's start making the handle.
Make a mark on the PVC pipe to get the handle to the desired length. The standard length is 25 cm. The following steps are not necessary, but they will give your lightsaber more personality. Wrap the handle in paper or cardboard, thus making a stencil, and spray paint the handle with the color you want. You can experiment with paint and stencils later. You can cut the bicycle tube into pieces of the desired length and stretch them onto the handle, making the grip more secure and comfortable. You can also make a belt and on it - a holder from a bicycle inner tube for a sword.
We continue to work on the handle. The Jedi must decide where he will place the sword's power button. Once you have decided on the location, drill a hole of such a diameter that the switch fits snugly in it. Cut a slot at the bottom of the handle for batteries. To do this, use a PVC pipe cutter. If the length of its blade is not enough for you, use a hacksaw.
Let's start creating the blade. 
1. Forge a blade of the required length - about 75 cm, depending on the height of the Jedi (use a hacksaw to cut polycarbonate).
2. If the blade is not translucent, it needs to be made so. Any method that allows the light to diffuse will work. Here are two ways to achieve this. The first is the sandpaper method. Sand the pipe lengthwise until it becomes almost white and you can no longer see yourself reflected in it. The second is the tissue paper method. But before performing it, you must first take the next, third step. Then carefully wrap the blade in one layer of white (though any color will do) tissue paper. Secure it with clear packing tape and wrap it around the full length of the blade on top to keep the paper in place. 
3. Select which end of the tube will be the “point”. Measure 0.5 cm from the opposite end. Then carefully wrap the blade with electrical tape, limiting yourself to the mark you made, until the blade at this point is thick enough to be inserted into the handle without falling out or wobbling.
Additional steps:
4. Find a piece of stiff wire or wood that needs to be cut to the exact dimensions of the outer diameter of the "blade" pipe. It should be long enough not to fall in and short enough not to protrude beyond the pipe wall. You'll need to tie a string of LEDs (which we'll make in the next step) to this crossbar, which will keep it from sliding down the tube. Another such crossbar should be installed at the base of the blade for the same purpose. This step is optional, but doing it will improve the lightsaber's performance and durability.
5. Glue the foil as close to the “point” as possible. This will reflect the light from the end back into the tube. If you decide to mount the LEDs on the crossbars, tie them first and only then stick on the foil.
We make a chain of LEDs.
1. Strip two pieces of wire completely so that there is no insulation left at all. 
2. Take one of the bare wires and screw the positive terminal of the LED to it, at the very beginning. You can determine the positive terminal by its length - it is longer than the negative terminal. 
3. Continue attaching the LEDs with the positive terminal to the wire down its length. Screw each subsequent LED where the “positive” leg of the previous one ends. 
4. When you have thus reached the required length, do the same with the negative terminals of the LEDs. How it should look is shown in the image.
5. Use wire cutters if necessary to cut wires.
6. If the wires are shorted, the blade will not light up! Make sure the wires are not touching each other.
7. If you made crossbars for tying a chain of LEDs, then attach its upper end to one of the crossbars. Pass the chain through the tube and attach the bottom crossbar. If you add a foil reflector on the bottom, it will also help the blade glow brighter.
Let's continue. If you are going to use a motor: wrap a piece of wire or carefully glue a nut to the motor shaft so that it is as unbalanced as possible. This will make it vibrate more, which will make the sound effect better. Also, if the motor is too small to fit snugly against the sides of the handle, wrap it with masking tape to keep it firmly inside. Your switch and motor wires should be long enough to connect to other components on the outside, 7.5cm from the bottom end of the handle (to allow room for splicing and soldering). 
The wires on the battery compartment may not be too long, just long enough to connect to the contacts. 
1. Make sure the hole switch button works. You will need enough clearance inside the tube to accommodate the contacts and wires. 
2. Solder the wires to the switch and thread them through the hole in the sword handle. If you don't have a soldering iron, you can wrap the bare ends of the wires around the pins and wrap them with electrical tape. However, a soldering iron will work better in this case.
3. Attach the blade by inserting it into the handle with the LED string wires protruding from the bottom of the handle.
4. All components should be soldered in parallel to the battery with a switch between them. In the example, it is made so that the red wire is “plus”, the white wire is “minus”. Black is traditionally "earth". Keep this in mind!
-solder a weak resistor (~10 Ohm) to the white contact of the motor (this will supply the LEDs with a higher current). Which of the motor contacts will be negative is chosen arbitrarily, we just need to monitor the connections.
- Solder the white wire of the switch to the red wire of the battery compartment.
- Solder the red motor terminal and the red wire from the LEDs to the red wire of the switch.
- Solder all the white wires to the white wire of the battery compartment.
5. Carefully insert all components into the handle so that they fit snugly in it, while the motor shaft should not catch anything inside. You may have to place the wires on the outside of the handle if its internal diameter does not allow everything to fit inside without difficulty or interference.
If the blade doesn't light up, first check the LEDs (for positive and negative contact) and the motor (if its shaft is touching anything inside, there may be a problem).
There are many variations on how you can make a lightsaber with your own hands. The above is one of the simplest, one might say basic. If it doesn't satisfy you, use your imagination. You can make an elegant handle, age it with paint and sandpaper, and experiment with the color of LEDs. Don't stop there and may the Force be with you!
How to make a Jedi sword with your own hands aslan wrote in January 6th, 2018
In this post I will tell you how to make a lightsaber entirely with your own hands:
First, we need this diagram with drawings of the original handle.
As a basis, I took a gray plastic PVC pipe with thin walls with a diameter of 40 mm. I don’t remember the exact name, but in a hardware store you can easily find it in the plumbing department.
We mark the length of the future handle on it. 
Print it out and put it on the pipe: 
Let's cut it off. It turns out like this: 
Drilling holes in the ears: 
We attach it to the handle according to the diagram, mark the position and make a cut for the power buttons. 
And glue it 
Now that the glue has hardened, we smooth everything thoroughly with fine sandpaper and go over the entire surface of the handle. After this, using a solvent, degrease the entire surface of the handle, prime and paint. 
After the first layer has dried (in about a day), add plastic decorative elements according to the diagram and paint again. 
This is the paint I used 
She's the best fit. Before this I used cheaper paint from FOX, it turned out to be terrible, it turns dark when touched, and after varnishing it turns completely dark gray.
According to the diagram, we make a ring and paint it in the same way, maybe in one layer. 
After the paint has completely dried (after 24 hours), coat the handle with glossy varnish. 
We cut out the last design elements from plastic according to the diagram, glue them with the letter T, paint them matte black and glue them to the handle.
This turns out to be such a great handle. 
Now about the filling.
All the filling is assembled according to this scheme: 
A 12-volt battery can be purchased at an RU toy store or an airsoft equipment store. The 12 - 5 volt converter is a regular car USB charger for the cigarette lighter.
Sound cards may be different. I usually take from HASBRO swords, but now they sell cheap swords at Fix Price, they have an identical copy of the HASBRO sound card installed, apparently someone was not too lazy to copy it. The sound quality is excellent.
You also need a speaker, it is best to take it from a portable acoustic system. 4 watt 4 amp speakers are best, they are bassy and vibrate well.
For all this electronics you will need a chassis so that you can easily disassemble the sword at any time for repairs or upgrades. We cut it from the same pipe, I got something like this:
We insert it into the handle, mark the hole for the button and fill it:
The next in line is the battery, the positive wire is immediately connected to the button. 
And then according to the diagram, all the rest of the electronics. It is very important that the 5 - 12 volt converter be connected after the button and not before it. 
Now all this stuff can be attached to the handle 
We add a button cut from a SEGI cartridge, and put plastic on the bottom so that the buttons can be pressed and that’s it. 
This is the beauty we got
