How to Make a Lightsaber Hilt

Instructions on how to build your own lightsaber hilt from Star Wars!

All of the parts that I bought for the lightsaber I bought from three different stores and websites:

• Ultrasabers
• Custom Saber Shop
• Home Depot!!!

Parts That I Used For My Lightsaber Hilt

• 1-1/2" x 12" chrome plated brass sink tube
• 1.5" sink tube adapter
• Graflex replica red button thumb screw
• A washer big enough to fit over the threaded end of the button
• A bolt small enough to fit the button
• Set of 6 piece 3.6" grips
• Prophecy pommel

Supplies I used:

• Ruled paper
• Pencil
• Tape
• Dremel
• Medium grit sand paper tip for Dremel
• Fiber glass reinforced cut-off wheel for Dremel

Try to apply these as even as possible and it even helps to put a thin piece of paper at the bottom just to make sure all of them are level.

Screw the pommel into the sink tube adapter until it feels snug. Then you can use epoxy and fit the adapter into the hilt base.

This Step requires a piece of paper and a pencil. Using the diameter of the sink tube, draw out the shape using a ruler so that it will turn out as precise as possible. Once finished with designing, wrap the paper around the top of the tube and tape it so that it will stay in place for the next step.

For this step, use a drill to make a hole a little more than two of your hands from the bottom so that it will fit you perfectly.

Using a fiber glass reinforced cut-off wheel accessory for a Dremel and follow the design from the last step. Don't attempt to cut the curves on the blade holder if there are any because that will be gone over with sand paper or a Dremel. With the rough outline of the blade holder, use a Dremel to make the edges curved and the lines smooth.

For this stage of the process, all you have to do is stick your fingers inside of the saber hilt with the washer and place it over the hole you made earlier. Stick the button you have through the hole and the washer and then carefully screw the bolt on as tight as possible.

From here, your lightsaber hilt is finished. You can deck it out with electronics and any other things you would like to add.