Nerd Bird 101: How to build a lightsaber
Hey friends,
I’m just gonna come out with it–I love Star Wars, and any paraphernalia related to the films. I have 2 toy lightsabers [1 Anakin; 1 Obi-won] and have gifted a Yoda, Dooku, and another Obi-won to my closest friends…so technically, I have bought them all! I also have an old cardboard lightsaber that a good friend of mine painted–but none were nothing compared to this Master Replicas Force FX Saber.
As you can see, that item is beautiful but really expensive. Plus, a big part of Jedi training is learning how to do things by yourself. So, there was only one solution left: I had to build my own.
I read a lot of websites, but wasn’t quite sure where to start. I enlisted the help of someone known on the forums as Novastar…and was glad to find out that he was relatively local. Matthew Carrauddo from The Cutting Edge was kind enough to stop by popSiren and show me how it was done. Then, I spent some time building one on my own. Want to see how it turned out? Check this out, padawans (and stick around for the bloopers at the end, pretty funny)!
If you want to know how exactly to build it and get a list of materials, see the show notes here. Now for some pointers:
1. Take Matthew’s advice; Try to get a narrow tube
I learned that bigger is not always better. Because my tube was 2″ in diameter, I had to get larger parts to accommodate it. However, finding a cost efficient thin LED Flashlight would have been even tougher if I went with the thinner sink part. Pick your battle, I suppose.
2. Use light parts, your arms will thank you!
I ended up using plumbing parts because of my large and in charge tube. Sink parts are much, much, lighter making it easier to maneuver the saber. Although, I gotta say that my guns look pretty good after toting that bad boy around for a few days :)
3. Be patient and keep focus
Building lightsabers can take some time. Understanding how it all comes together, and tweaking it for yourself can be frustrating and time consuming. Also know that this will not be your last lightsaber.
On that last note, I have to say that it’s a bit of an obsession. I want one thats even more realistic, and with noise. I’ll be tooling away in my workshop, and I’ll keep you posted on what becomes with this project. Try it out, and show me what you make!

Not a Star Wars fan, but I am a Neha fan! Dugg the segment and the lightsabers look kick-ass.
Just found this blog in the blog-o-sphere! I must say, a cool blog and a hot you( courtesy: “Sinp-Snaps”! :)