TrooperTrent Holiday Special Lightsaber Series

[Halliwax]

TrooperTrent's Holiday Special Kit

A lot of information has been discovered in the links below. These threads should be consider a archive for the Holiday Special
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Neorutty's HS thread
Paul Duncan Archives book

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INDEX

Part 1
-Dissasembly of the flash, tung mod and thread removal

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PURCHASE KITS HERE!!!!!

Unlimited Run - Holiday Special Lightsaber Kit

It's everyone's least favorite, and hideously ugly lightsaber! The infamous Holiday Special lightsaber! This ugly prop was cobbled together after completion of A New Hope in preparation for the filming of the Variety special that would air only one time (and for very good reason) after all of...

www.therpf.com

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UPDATES
- 2/18/19 Released Disassembly video
- 3/6/19 Released Control Box video
-8/25/19 Released Tinkercad Switch STL

Video Series Tutorials

2/18/19 - Episode 1 Disassembly of flash, Tung fabrication, Thread Removal

2/23/19 - Episode 2 Shroud Fabrication




Material / Parts / Paint
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TrooperTrents Holiday Special Kit
STL File for Switch
Korbanth T track (or track of choice)
Aluminum Sheet (shroud)
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- Rustoluem Flat Black 7578
Blue Painters tape
E6000
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TOOLS

Aviation Snips
Tweezers
Semi-Large Drift/ Nail set (nostril punch)
Mini Clamps
Hammer
Mini-File set


- Flat head screw driver
- Dowel
-Chop saw/miterbox hack saw
- Sharpie
- Mini file
- Nail set
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[Halliwax]

Welcome to our next new project series! TrooperTrent came to our rescue once again, now with this cool replica of the Holiday Special lightsaber! this next series of tutorials will cover everything you need, and the steps you have to take to get your Graflex 2773 to the highest level of accuracy!!

So first lets disassemble the flash, and do a few little mods! To begin the easiest thing to do is take some reference pictures of the 3 small screws we have to remove and 2 large ones. the 3 small screws, 2 are the same, and 1 is different to remember where the different one goes.

Screw 1

Screw 2 is located on the other side, below the "tung pin" we will get to the tung pin soon!

ok so next we have to remove the 2 large screws holding down the red button shroud. once you remove this you will find the last small screw that needs to be removed

screw 3, this is also a good time to locate the orientation of the selector switch. white dot was lined up with the N on the flash shroud

Now the flash socket should be completely free from the aluminum tube. you can simply push it out by removing the black end cap, and shoving a dowel, ruler or some object longer then the flash

The tung is clipped in and you need to depress it in order to move the socket. I use a nail set to push the tung pin in, then use the dowel to push the whole assembly out the top. watch your eyes! the tung springs out!

ok, so you notice the top part of the socket comes out with the tung, hold that tung tight! she's a bouncer!

continue to push until the second part comes out! be careful not to lose this locking block!

with the flash now completely hollow we can mod the tung. we take the tung piece and bend it to a 90* angle like below. then take the tung and bend if over the metal ring that is kept inside the top part of the socket. so the tung should look like this

space it so the tung is centered in the top part of the socket. (see the socket in the top left of this picture)

your going to have to sand a notch into the groove the "ring" falls in. now with the tung wrapped around it its much thicker and wont fit in. 2 minutes with a small file and it will fit like a glove!

now with the tung centered we can re assemble the flash. so work in reverse, this can be tricky because the locking block will fall.. make sure the locking block is also installed like this. with the screw hole closer to the center

if you installed it correctly, the tung should be solid in there now. that ring, locks the tung in place.

also gives it a real "star wars" feel with the bulb release below it.

Next up, we have to remove the threads on the flash. this can be kinda tricky... if you have a chop saw with a metal blade its easy beans. as i did it that way in my youtube video. but if you don't have a chop saw, you can use a miter box, with a hack saw blade. take your time, and cut slow and it should come out straight.

you can grab this miter box here at home depot
Stanley Deluxe Miter Box with Saw-20-600D - The Home Depot

there is going to be some small burs on the end, lightly hit the edge ( NOT THE FLASH FINISH) but just the edge with some sand paper to remove the burs. this will make the End Cap, Trent supplies with the kit fall right in!

thank you for your time!

 

[Halliwax]

please reserve this post 2

 

[Halliwax]

please reserve this post 3

 

[Halliwax]

please reserve this post 4

 

[Halliwax]

Please reserve this post 5

 

[OdiWan72]

WOHOOO...I already love this thread.

thanks so much gentlemen

 

[nailuj]

This is great. Roll on posts 2 to 5. Love the way you are doing this in stages. You got me hooked.

 

[Sundowner]

I’ve been waiting for this!!

 

[teecrooz]

I have my TrooperTrent kit 2 arriving today and am all caught up other than cutting the threads off!

 

[TheUnchosenOne]

It's no Graflex, but as it's own thing, I actually really like the Holiday Special lightsaber

 

[Halliwax]

I have my TrooperTrent kit 2 arriving today and am all caught up other than cutting the threads off!

Chris how are you going to go about cutting the thread off?

 

[Halliwax]

It's no Graflex, but as it's own thing, I actually really like the Holiday Special lightsaber

It’s the ugly duckling, you just have to love it

 

[Halliwax]

This is great. Roll on posts 2 to 5. Love the way you are doing this in stages. You got me hooked.

Gonna try and have this banged out this week. Double checking some things with Trent tonight and then working on this again tomorrow

 

[TheUnchosenOne]

It’s the ugly duckling, you just have to love it

It's kind of what I'd have expected Luke's Jedi lightsaber to look like, in another world: thrown together by a guy with some blueprints and a little technical know-how but no actual guidance whatsoever

 

[teecrooz]

Chris how are you going to go about cutting the thread off?

Either hacksaw or dremel cutting wheel and a bit of sanding and filing.

 

[Halliwax]

Either hacksaw or dremel cutting wheel and a bit of sanding and filing.

Excellent!

 

[Sundowner]

Im sure it was addressed but was the lettering taken off or are the reference pictures too low res?

 

[Halliwax]

Im sure it was addressed but was the lettering taken off or are the reference pictures too low res?

They must have removed the lettering on the graflite

IF they used graflite, the t track and box covers the graflex logo pretty good

Can’t really say which version they used, but for use either works for us

 

[Sundowner]

They must have removed the lettering on the graflite

IF they used graflite, the t track and box covers the graflex logo pretty good

Can’t really say which version they used, but for use either works for us

The same for the tiny lettering in between the ports on both versions?