How to Make a Lightsaber With Polly Plastics

Hello Cosplayers, Makers, Star Wars fans. See how Thomas makes a cool Lightsaber with common hardware and flashlight parts, along with Polly Plastics Moldable Plastic.

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• Polly Plastics moldable plastic
• 12 inch PVC drain extender
• Sink drain replacement kit
• Random parts (Thomas uses flashlight pieces, Super Soaker parts and metal washers in this build)
• Rust-Oleum Hammered Enamel Paint
• Rub ‘n Buff Wax Metallic Finish – silver and gold
• Super Glue/ contact cement
• Dremel tool
• Hot glue gun with glue sticks
• Cutting tools
• Leather (optional)

• Draw a line on the PVC drain extender about 5” from the smooth end of the tube.
• Use the Dremel to cut off the 5” piece.
• Cut a rectangular slot through PVC part from the drain replacement kit.
• Find your random parts that you can fit onto the PVC pipe. Here Thomas uses Super Soaker parts and flashlight parts. Attach with hot glue.
• Heat ½ cup Polly Plastics moldable plastic, following the usage instructions, and use the molten Polly Plastic to secure your random parts to the PVC pipe and fill in any gaps.
• Continue adding the rest of your random parts. Add enough moldable plastic to smooth and bevel all edges.
• Insert the metal sink drain part into the end of the PVC slotted part.
• Use Super Glue to glue any random metal parts onto other metal parts.

• Use Rust-Oleum Hammered Enamel for the base coat for your lightsaber. Do not paint the metal sink drain part that fits into the PVC pipe.
• Brush Rub ‘n Buff over the surface of the painted parts. Add a bit of water to the paste to make it easier to apply. Apply silver and gold to the get the look you want.

• Cut a piece of leather and attach it onto the lightsaber handle with contact cement.
• Re-install the metal sink drain part unto the end of the lightsaber.

Here is a picture of your finished Lightsaber.

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