Build your Own Lightsaber - Instructions on How to Make a Lightsaber

All Star Wars movie fans will be able to easily identify a lightsaber, as it was this movie series that immensely popularized this remarkable sci-fi device. A lightsaber, also known as a laser sword, is a unique and versatile device that can cut through almost anything, in a matter of milliseconds. It is a kind of sword, which, instead of a metal blade, has a column of colored energy, and is also regarded as a laser weapon. The blade, suspended in the column, is made of plasma energy, which is emitted by a hilt, controlled by the wielder. Those who are fascinated by this sci-fi device, especially children, would want to have a lightsaber of their own. If you are wondering, how to build your own lightsaber, you can follow the below mentioned instructions on how to make a lightsaber.

Build Your Own Lightsaber - A Step-by-Step Guide
Building you own lightsaber is easy, inexpensive and can be great fun. At the end of the procedure, you would have a self-made tech toy, to boast about. Here's a list of tools and materials that you would require, followed by simple 'make a lightsaber' instructions.

Materials and Tools

Materials for Blade Construction

• Duct tape.
• Solid wires (22 gauge).
• Polycarbonate tube with an outer diameter of at least 0.75" (but less than the inner diameter of the handle). It should be around 2.5 ft. in length.
• 25 to 35 single colored LEDs.

Materials for Handle Construction

• 1.25" diameter or larger PVC of around 8 - 12 inches.
• Battery pack (2 - 4 AA batteries).
• A switch or push 'on and off' button.
• A small motor for creating vibrations and some sound effects.
• The length of the handle and the blade put together, should be 3 inches.

Tools

• Drill
• PVC cutter
• Soldering setup
• Hacksaw

Lightsaber Construction

Step 1 - Constructing the Handle: Measure the desired length of the handle and cut out the PVC, with a PVC cutter. Then, cut out a slot for the battery pack, in the bottom of the handle, drill a hole to place the switch wherever desired, and then fix the switch there.

Step 2 - Constructing the Blade: To form the blade, cut out a blade of the length desired, from the polycarbonate. You can make the blade translucent, if it is not so, by rubbing sandpaper through the length of the blade, till the surface is almost white and the blade is not seen. Then, take the other end of the blade tip and measure and mark 0.25 inches from the bottom. Wrap a duct tape around the marked point, to make this point on the blade, thick enough to wedge firmly into the handle.

Step 3 - Constructing the LED String: Take two wires and strip off their insulation. Attach the positive side of the LED to the top of one of the wires. The LED will have two metal legs, and the longer one of the two is its positive side. Continue attaching the LEDs down the length of the wire, till the desired length is achieved. Each LED should be placed at the tail end of another LED and the same procedure should be repeated with the negative side. Make sure that the positive side does not touch the negative side, as this can cause a short circuit. The blade will not light, if this happens. Place the string of LEDs in the blade and attach them to its bottom.

Step 4 - Electronic Set-up: Make sure that the switch is fixed properly and then attach the LED wires and leads, using a soldering setup. Attach the blade to the handle, in a way that the LED wires protrude out of the handle. Solder all the loads across the battery pack, keeping the switch in between. Then solder all the wires of the motor to the wires of the battery pack, and insert all of it into the handle. Make sure that they fit properly. The wires are to be arranged, so that they are not jammed together, and that the motor shaft is not touching any of the other components. Your lightsaber is ready for use.

The steps mentioned above are just one of the many ways to build your own lightsaber. Now that you have finished with the lightsaber construction, try if it works, rectify the errors in construction, if any, and enjoy your self-made lightsaber.