After looking at hundreds of light sabers online and not getting exited to build any of them I decided to design my own, this is Project SLS.
With over 140 parts this light saber has full internal detailing and is able to be easily separated to show them off for display.
Features of the light saber include.
Removable power cell
Light up crystal
Ratcheting blade length adjuster (decorative no blade is included in the project)
Sliding power adjuster (also decorative)
Belt clip and D-ring
After completing this project I though it would be fun to create a full set of instructions. So in the download you will find detailed assembly diagrams, a complete bill of materials, project notes, full material source list, and additional printing and assembly tips.
I also a made a display stand and belt holder. They are uploaded separately and can be found here. https://www.thingiverse.com/thing:3719865
Please refer to SLS_Instructions_v1 for print setting for each part.
The whole thing was modeled and diagrams created using Siemens NX12. Many of the elements of the light saber were influenced by projects I have work on or have seen in the uncountable number of devices I have dissembled or studied.
I learned how to solder for this project, so my electronics are very simple. I hope to do something more advanced next time.