I learned some things about these sabers today. My cast is rather shrunk, every LED bar is the same size, it’s a standard 25 by 10 ish mm.
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So, since it was not well captured, I replaced this greeblie too. I drilled 4 tiny corner holes, used a dremel cutting bit (cylinder) to basically mill this box out by hand! I used triangular and rectangular files for the corners.
I tried cutting a bargraph shorter, it looked stupid and then I realized that the depth I had estimated equaled the whole box, just with the legs folded under! It sits proud just the right amount. Personally I would have made it flush.. my trimmed box fell in too far and it looked nice.. anyway
Now,, spurred by that success I tackled the LEDs. I have a version that is so close, even the LED glass has the same egg shape
So, I’m assuming they didn’t cut the glass, because the prop had LEDs that are poking out further than stock. If you trim the bezel, you can literally calculate the height. The bezel reduces inside and a lip on the glass catches it. Shorten it, you’re just shortening the place where the glass stops. Neat right?
So in figuring that out, they drilled pretty deep. Deep enough that they probably blew out the side of the box a little bit. (Mine is worse because of my shrunken cast)
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But I was able to mock up the LEDs poking out the same amount!
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I have to shim the rectangular hole.. I cut it .8mm too long, but a scrap of resin or some putty will fix that right up