Sub Miniature Lightsaber

Here is a fun yet serious project for all of you young Padawans. Today we will build a sub miniature Lightsaber. This project does require a metal lathe but every process is fairly easy. Please keep in mind that any or all steps can and should be modified to suit your own needs or skills. This sub miniature Lightsaber looks good just sitting on a shelf but could also be attached to a young Padawans belt. This project has a build time of around 2-3 hours. Total length is a little under 6 inches. Future refinements or embellishments can be added at any time if you need to upgrade. Now go forth and create. May the force be with you....

Metal Lathe

Drill Press

Various drill bits

1 inch diameter aluminum

1-1/8 inch diameter aluminum

1-1/2 inch diameter brass

3/8 inch diameter brass

1/8-27 tap and die

5 inch length of 1/8-27 threaded rod (Standard Lamp Nipple)

The emitter housing is machined from 1-1/2 inch diameter solid brass. The final shape will resemble a bell but feel free to modify to your liking. This bell shaped emitter housing will have 1/8-27 threads on the back end to attach to the handle.

The emitter is machined from brass and will have a diameter of 3/4 inch with a length of 1 inch. The back end will be drilled and tapped for 1/8-27 threads. The front end will have a 3/8 inch hole about a half inch deep. Sand and polish.

The main handle section is machined from 1 inch diameter aluminum. This piece is 555 inches long and has a through hole in place. If you start with a solid rod, you will have to drill a 1/2 inch through hole. The front end will be concave to accept the emitter housing. Machine equally spaced grooves about 1/8 inch deep. These can be left as is or rubber O-rings installed later. I will install the O-rings as I like the finished look. After the handle is machined, sand and polish for a shiny look.

The end cap is machined from 1-1/8 inch diameter aluminum. Drill a through hole and tap for 1/8-27 threads. The front end has a shallow raised lip to align the final assembly. The end cap is about 1 inch long. A brass lanyard will be attached to the end of the cap.

The lanyard is machined from 3/8 inch diameter brass and is about 3/4 of an inch long. Machine a ball on one end and cut 1/8-27 threads on the other end with a die. Two 1/8 inch holes are drilled into the ball on opposite sides the lanyard ring. The ring is made from 1/8 inch brass rod. This ring is a little tricky to bend properly so take your time. Use smooth jaw pliers to prevent marring. Carefully open the ring just enough to slip into the holes and press into place.

Here I have chosen green plexiglass for the emitter tip. Machine for a snug fit. Sand and polish about a 1/4 inch of the exposed end. If you machine this part too loose, just add a drop of super glue to hold in place.

The assembly is very straightforward. Screw each end to the threaded rod and you are finished! If there is some looseness, trim the threaded rod slightly until the fit is tight.

I hope the force has been with you during this instructable. While the finished size is too small for an adult, it may be just the perfect size for a young Padawan. Now go forth into the world, be kind and stay happy.