Build Your Own $25 Jedi Apprentice Lightsaber

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Build Your Own $25 Jedi Apprentice Lightsaber

My 5-year-old finally asked me that question that many geek dads so look forward to: "Can I have a lightsaber?"

Now, lightsabers aren't cheap, and true Jedi Knights make their own. But somehow I just can't see Master Yoda asking the younglings to whip out the soldering irons. I have a sneaky feeling the younglings get loaner sabers.

Coruscant is (as you may be aware) in a galaxy far far away, and I just can't pay the shipping fees to have one sent our way.

So... Home Depot, here we come.

Our design is based on the $33 Lightsaber in 33 Minutes plans found on Instructables.com -- here's the original link.

I should explain that the saber I constructed differs slightly. The $33 saber uses an extension piece (1-1/2" diameter) that I felt honestly made the entire saber just too bulky. Rather than add it, I skipped the extension and inserted 10 1-1/4" gaskets (inside diameter) over the bottom of the pop-up chrome assembly. I added the slip joint washer and its gasket that fits right under where the on/off button will go and then put on the 10 gaskets. 

I had a few junk pieces lying around that I used for the pushbutton and the bottom piece. To keep with the rubberized feel of the gaskets I also sealed the bottom piece on by wrapping it with a rolled piece of black Sugru (sugru.com).

All in all, I spent a total of $22.82 plus GA sales tax. Keep in mind I used a junk drawer button and bottom, so your cost might be slightly higher if you have to source items to fill those spots.

Entire thing took me less than 23 minutes to build so I'm calling it the $23 lightsaber in 23 Minutes.

If anyone knows where I could find some stiff foam that would hold up nicely and can retain its shape, that might be an option, so let me know if you have any suggestions.

Parts Used (from Home Depot):

DBHL Plastic 2-Piece Pop-Up Assembly in Chrome: Model # H756-1, Store SKU # 736061, $7.29

Qty: 1

Link: http://www.homedepot.com/h_d1/N-5yc1v/R-202078178/h_d2/ProductDisplay?catalogId=10053

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Danco 2 in. x 1-1/4 in. x 3/8 in. Basin Mack Gasket: Model # 80346, Internet # 100163238, Store SKU # 547761, $1.27

Qty: 10

Link: http://www.homedepot.com/h_d1/N-5yc1v/R-100163238/h_d2/ProductDisplay?catalogId=10053

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Nut/Washer 1-1/2 x 1-1/4 in. CP Nut/Washer, SKU# 041193028952, $2.83

Qty: 1 (shown with gasket in image below)

Link: http://www.homedepot.com/h_d1/N-5yc1v/R-100163238/h_d2/ProductDisplay?catalogId=10053

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Location: Atlanta, GA
Members: 5
Latest Activity: Aug 7, 2012

Discussion Forum

Pre-apprentice version?

Started by Daniel Brisson. Last reply by James Floyd Kelly Aug 2, 2012. 1 Reply

I would like to try to build a chew toy (completely non-toxic and safe) version of a lightsaber. Anyone has any ideas? I was thinking that I should use parts from other toys to make sure they are…Continue

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Comment by James Floyd Kelly on August 7, 2012 at 2:04pm

Hi, Doug. The problem really is space. The inner diameter of this particular design is less than 1-1/4" so a lighting option would probably work (battery, LED, resistor) but adding sound would pose an issue. Radio Shack sells a $12 portable recorder with tiny speaker that can hold about 10-15 seconds of sound but the sound quality is not good and not loud at all -- it would fit inside but would require some work to make the button to trigger the sound work.  I've not yet checked but I do hear there are more professional saber sellers online that have sound options, but again... no idea about their price or size.

Comment by Doug Messinger on August 6, 2012 at 7:14pm
I made this last Halloween. I would love to add the capability to light up and have sound. Any suggestions?
Comment by James Floyd Kelly on August 2, 2012 at 1:08pm

Thanks, Rob.  As stated in the writeup, however, I can't take credit for design. The $33 saber tutorial on Instructables pointed me in the right direction. But that's what was so fun about doing it -- modifying it a bit and making it unique. The $33 recommends a larger extension that slides over the original 1-1/4" diameter pipe and it really felt too large in my hands... so I couldn't see my son having too much fun with it.

Check this out, btw... one happy apprentice.

Comment by Rob Keisacker on August 2, 2012 at 12:51pm

The plumber's aisle is a WONDERFUL place for that isn't it!!  :)

I made one for my son last year for our yearly trip to Disney for their Halloween party, but your lightsaber is MUCH better than the one I did.  Great job, and great tutorial!

Comment by Nathan Barry on August 1, 2012 at 3:22pm

I'd totally do this project if I had a son!

 

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