Making a Obi-Wan motorized stunt from a cheap Chinese Luke v2.

[Steiro912]

Hi.

So I'm not very good at documenting my builds, but I thought this was a small and easy project that could be fun to folllow.

I bought a lathe last year, been wanting one for years. And one of the missing sabers that I haven't done yet is a ANH Obi-Wan stunt.
Browsing Aliexpress late one evening I found a saber that might be a good base for the project, so I ordered a couple.

Let's see how it turns out, this is what I ordered:

 

[Steiro912]

...and this is what showed up in the mailbox. Not exactly like the picture, but hey...

It's not that bad actually. Apart from the weathering, which could not fool a small child. In the night.
But mechanically and dimension wise it's pretty ok.

I'll take it apart and start making some small changes that hopefully will make it look like a proper motorized Obi stunt.

 

[Steiro912]

Right, so let's start with the pommel, the part that I think will require the most work to look like it should.

I need to fix the ugly sound vents, remove the "not such a mystery chunk anymore", replace the D-ring and do something about the horrible chemical "weathering".

 

[Steiro912]

I ended up sanding off the weathered layer first with some fine sandpaper and 3m scotch brite pads.
Then it went into the lathe to remove the chunk and sound vents.

 

[Steiro912]

Now to make a plug for the big hole I just made. And drill a hole for the motor wiring.

 

[Steiro912]

And here's the result, finished off with a correct D-ring from roygilsing at Wannawanga. I'm pretty pleased with how it came out. Fortunately nobody knows it came loose from the lathe while machining. If anybody asks about the scuff marks I'm definitely claiming screen accuracy.

 

[Steiro912]

The next piece was a little easier, one minute of sanding and a trip to the drill press.

 

[thd9791]

this is wild - interesting to see one of those cheap chinese sabers. A few companies I think completely copied some Anakin Starkiller hilts and there was some drama

you're going to learn so much about this saber trying to fix it, I've done this with projects and afterwards i felt like I understood the prop better. Your endcap alone is a big deal!

 

[Steiro912]

Next was the clamp section. The inner diameter is much too big for the electric motor I got, so needs a simple adaptor.

 

[Steiro912]

Another piece of aluminium in the lathe... And a couple of M4 hex screws to hold the motor.
Next i also did drilled and tapped two hex screws in the clamp cage to secure the adaptor that secure the motor. You get the idea. Came out pretty good I think.

 

[Steiro912]

Here is the completed part, added a bubble strip and a v2 lever from Wannawanga.
The China-clamp is not very accurate, but since this is a low-budget build, it will stay, and can easily be changed later.

 

[Steiro912]

Grenade section only needed to have the inner diameter opened up a little, and a coat of paint.

 

[Farrells Props]

Gorgeous work!!

 

[Steiro912]

Only the emitter left, first removed all paint with some thinner, then made an adapter for the ball bearing.

 

[Steiro912]

It's around -10C outside, and no heating in the workshop, so painting was done with a spray can on the porch, and cured in front of my wood burning stove.

 

[Funky]

This is turning out nice! I may pick up the same saber. Could you provide a link to wear you bought it?

 

[Steiro912]

Thanks! Sent you a PM.

 

[Steiro912]

Then I cut a piece of 8mm stainless roundbar, chamfered the ends and attached a coupler for the motor.