Two Hour Lightsaber

Is it possible to build a quality Lightsaber in only 2 hours? If using modified existing parts, the answer is yes. I have gathered up a small box of "things" that were laying around my shop. By modifying any or all of these parts, a quality Lightsaber could be constructed in 2 hours.
This instructable will demonstrate how to build a quality Lightsaber from literally any found objects. This project will require a metal lathe and drill press plus a few hand tools....hacksaw, files, taps, etc.
Any young Padawan can dig around in the garage or basement and find enough interesting items to build a quality Lightsaber.

A Box of Small Interesting Parts
Various Diameters of Scrap Aluminum and Brass
Metal Lathe
Drill Press
Drill bits
Hacksaw
Vise
Taps
6/32 Set Screws
Fine Sandpaper

These parts were chosen from many 100's of items laying around my shop. If you can't find usable parts at home, dig around in friends garages or junk yards till you can aquire a nice selection.

When you have enough parts, lay them out to see what can be done with them. I always like to start with the front emitter of a Lightsaber. As you are building, rearranging the original parts layout is often needed. Always remember, it's your Lightsaber. There is no right or wrong way to build it.

The emitter will be the front section from a brass fire nozzle. About 2 inches of the end will work fine. Machine any markings or engravings off for a better look. Cut off and machine the other side.

A 3 inch piece of 1-1/8 inch aluminum tubing is machined to tightly fit into the emitter. Press fit on a vise to permanently attach. Now machine a bushing from aluminum to tightly fit into the emitter shaft. Press into place for a permanent fit.

Here is a small stainless steel pneumatic motor with a 5/32 inch chuck. This part is perfect as it fits tightly into the emitter and allows you to chuck something in for a finishing touch. Now you have the ability to remove and replace the tip to suit your needs.

Machine the leftover knurled section of the fire nozzle for the barrel assembly. A 1-1/2 inch diameter brass gear is machined part way to fit into one end. Round over the other end of the gear for a nice transition. Press together for a permanent fit.

The handle will be made from an old spring loaded grease tool. Remove the internal mechanism and give the outside a good sanding and polishing. Machine a brass bushing that will connect the handle to the barrel assembly. The handle and barrel assembly are then pressed together for a permanent fit.

If you wanted a permanent fit, you would machine the emitter bushing shaft to be tight and then pressed into the handle. In this case however, the emitter bushing is machined to slide onto the handle. Drill (6) evenly spaced 7/64 inch holes on the emitter shaft and tap 6/32 threads. Now attach to the handle with (6) set screws. If you want to hide the mounting set screws, machine a brass collar with a snug fit. After the set screws are tighten, firmly slide the collar into place.
This method of attaching will allow for future upgrades if needed.

I had parts to an old pair of binoculars and one of the brass eye pieces was a perfect fit. Just tight enough to remove and operate the drill chuck if needed but firmly stays in place.

This Lightsaber project took 2 hours and 6 minutes to complete. The total length is a little over 10 inches and weighs about 2 pounds. Since the grease barrel had a screw off cap, you now have a nice storage area in the handle.
All steps can and should be modified depending upon what you have at your disposal. This instructable demonstrates the possibilities of using just about any collection of small parts to build a quick Lightsaber. In this version all fasteners are hidden for a sleek look.
Future refinements can be made at any time but this Lightsaber is ready for battle. "Make" believe battle that is....young Padawans.
MAY THE FORCE BE WITH YOU