I just came across this old thread while searching to see if anyone had made a wand using fibre optics. I couldn't see any of the photos mentioned in this thread, so I'm not sure how the wands turned out. I've made many wooden wands, and decided to try to make one with a lighted tip using fibre optics. For me it was important to make it out of wood as I feel it gives it the correct feel and character. The wand is made with a shaft of maple burl and a handle of gaboon ebony:
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Here is a close up of the wand tip where you can see the fibre optics coming out. It is made up of 8 strands of 1.5 mm fibre optic that has been embedded into the wooden shaft. I held the fibre optics together using heat shrink wrap. The shaft was first ripped lengthwise in half, then a small channel was routed to accept the fibre optic bundle. In the photo it looks a little rough, but in real life it actually looks quite clean unless you get very close:
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The light source is a small (1/2" dia) led flashlight from Lee Valley which has been embedded into a hollowed out handle. The light is turned on by twisting the light, rather than by a button. This was accomplished by cutting the handle in two, and epoxying the two halves of the flashlight in each half. When in the ON position, it is very hard to see the gap in the handle, and when in the OFF position there is a gap of less than 1 mm visible. The amount of light is actually pretty good, and in my opinion, replicates what you see in the movies quite well:
This was a fun build, and now that I've made this prototype, I'll likely do some more as my daughter's friends see this and start asking for it