I dremeled out the crystal chamber window from the wee little flashlight, as well as the "vent holes" on the side. This flashlight was great, as I could use it's two screw off ends to attach it to the other internal segments. The crystal itself was cut from the invaluable ice-scraper's acrylic blade. For the internal mechanics of the crystal chamber I cut apart the accessories from the "Funtastic Police Play Set" which had a lot of great textures.
For the emitter I used the top screen from the microphone, but hollowed out the middle, then cut lenses from the pen and closet light to color and diffuse the LED's from the flashlight. I then glued these to the hollowed top of the flashlight.
would have some cool electronic guts, but it was totally empty inside. Thanks Poundland.
For the shroud I used the Aquafresh tube. They were polyethylene, and if I had to choose a least favorite plastic it would be polyethylene. Nothing sticks to it, it gets all hairy when you cut it, and sanding it is a ghastly nightmare. But the tube fit nicely, so there you are.
For the pommel I wanted something that had interest and spoke to the rest of the saber. I used two sections of Aquafresh cap, the reflector cup from the flashlight, and some of the EVA foam.
To light the crystal I needed a seperate light source from the emitter, as it's battery supply wouldn't cover enough LED's to light both. I used the blue LED rig from the ice scraper (why do you need a light up ice-scraper?) and cut it down to fit in the base of the crystal chamber. I then used some of the microphone wire to run the switch to the handle.
Next the unthinkable happened and I dropped up my DSLR taking photos during the build. So, the contest ended up being a lot more expensive than 20£. I am such a dumbass.
I finally figured out I could focus by getting it in range physically and manually shooting. I'm still out a spendy lens, but here it is. I used the decorative mirror the landlord put up to make my tiny flat seem bigger for the backdrop. For the paint scheme I was inspired by McQuarrie's original sketches of the stormtroopers holding sabers. The sabers they were holding in the concept sketch looked suspiciously like Obi-Wan's, so I pushed the design to look more sinister and mass produced. Initially I wanted to do a more elaborate paint job using some blue details, but ran out of time.
I think my favorite bit is the crystal chamber. The only part I ended up using from the bike pumps was the bit holding the crystal and the power switch. The blade adjustment knob is a screw cap from the corkscrew sanded flat. I was really impressed with how sturdy the switches from dollar store crap were.
The grips are cut from two layers of the EVA foam sheet. I couldn't believe they sold that stuff at Poundland. That was the biggest score of the whole build. The charge port is the tip of the pen used for the emitter lens.Thanks!!