Sidious repair/redux

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Tsi Talon
Site Admin
Posts: 17
Joined: Sun Jul 23, 2017 8:53 pm

Sidious repair/redux

Post by Tsi Talon » Sun Jan 07, 2018 4:27 pm

The current project is another for Jeff. This time he brought me a me a partially disassembled (he hand sanded some horrendously deep scratches out of it, and we will powder coat it again) Sidious hilt that already had an install done on it by a respected person in the community. This log will serve to chronicle the changes, fixes and some improvements.

First, some pics of the hilt, a majorly obvious problem, the holes are nearly 2mm off center of each other. I dont understand why the previous owner would have paid for this snafu or why the installer would have done a fairly good job on the electronics and snarfed on the hilt work.

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Onto the insides.

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I dont know what this was doing in there, looks like crap and is a badly cut piece of PVC plumbing pipe that was sanded with some very low grit sandpaper leaving nasty grooves. Presumably to make it smaller to fit the hilt?

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Wiring, it can be routed better, not sure why the green speaker wires are so long, they dont need to go very far. Also the speaker holder just floats in the hilt unattached to anything.

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By simply turning the battery around 180º and routing the wires through the chassis, the speaker holder can then butt right up against the chassis and be attached and secure. Some people make such a big deal about "exposed wires that might ground out" and pull stunts like this on unsuspecting customers.

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The first improvement will be to replace these switches with something a bit slick. Stay tuned to see what i have up my sleeves this time around :)

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Now, onto some custom pieces. I cant build or work on a saber and not make some one off pieces to make it a bit more special

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Mormegil
Posts: 4
Joined: Tue Jul 25, 2017 2:42 pm

Re: Sidious repair/redux

Post by Mormegil » Sun Jan 07, 2018 6:12 pm

AJ wasn't kidding about the scratches, which didn't really show on the pics I received from the previous owner (whom I begrudge nothing). What did show on the pictures were two major flaws I just didn't pay attention to: The holes for the activation buttons being misaligned (causing one button to be bent slighty downward and tight while the other one was more wobbly) and the curve at the top of the outer sheath having an obvious flat spot. I went ahead and brought the outsides down to the bare aluminum (except for the emitter) and hand-sanded a proper curve into the contour...before passing it on to AJ for some of his magic!
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Tsi Talon
Site Admin
Posts: 17
Joined: Sun Jul 23, 2017 8:53 pm

Re: Sidious repair/redux

Post by Tsi Talon » Sun Jan 07, 2018 10:08 pm

So, not much else to do but jump right into a couple of the fixes while i wait on some Delrin rod to come in the mail.

I could be wrong, but i think this isnt supposed to be pointing up like that...

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I removed almost 1.5" of wire from the speaker circuit, attached the speaker holder and rerouted the battery wires. There is just enough room to access the SD card slot even with the wiring running over the sound card. Sweet!

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The vent holes looked to be too small and Jeff had mentioned that the speaker seemed low on volume (possibly due to the busted speaker). I figured it couldnt hurt to drill them out about twice the size they were originally, but without cutting into the slope of the pommel. Hopefully this will help with the volume issue if the speaker wasnt busted when Jeff bought it.

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Tsi Talon
Site Admin
Posts: 17
Joined: Sun Jul 23, 2017 8:53 pm

Re: Sidious repair/redux

Post by Tsi Talon » Sun Jan 14, 2018 2:54 pm

The anatomy of a truly custom blade plug...

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This shows just how bright the LED's can be and it would take almost no time at all to cause temporary or perm blindness if you look at them directly. The purpose of a blade plug is so you can show off your saber, while muting the light output to a safe level. Even with a blade plug, its not advisable to look directly at the LED's.

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Did someone say kill keys? Red because the main LED's, blue because the FoC LED and purple because of the combo.

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