Monday, January 11, 2016

How I Build a PVC Lightsaber

Here’s how I go about building a PVC lightsaber.

1. I get my PVC stock and parts. 1” and 1-1/4” PVC, 1” male and female connector and black O-rings.

2. I cut the main body of the hilt from 1” PVC. I cut this stuff by hand. I don’t have a miter saw.

3. I cut the shroud and grip from the 1-1/4” PVC.

4. I make the templates for the grip and shroud. By the way a paper towel tube is excellent to use as a template for 1-1/4” PVC.

5. I pre-drill holes by all the curves and corners to make it easier to cut out. I then use my dremel to get a rough curve for the shroud. Then I take sandpaper and wrap it around a can of spray paint to get an even curve.

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