Polyester Padawan

One man's attempt to build some Star Wars stuff.
[ Padawan Sabre | Master Sabre | Jedi Belt | Japor Snippet ]

Lightsabre Construction

Padawan Sabre

As part of a Jedi's training, one must build a sabre of his own. For my first attempt at sabre construction, I did not yet have a rotary tool, or any tools for that matter. I borrowed a drill, hacksaw, shears and file from a friend and went to work in my living room.

My basic parts list:

Empty wire spool - from trash at work
12 volt valve - from trash at work
Garden tool with interchangeable heads - Home Depot
Pot Lid - from trash at home
Switch, LED, 90 degree connector - Active Electronics

basic components used in my first lightsabre

The wire spool and valve make up the emitter end, and the pot lid makes a great pommel.

I used a red LED and mounting kit and a small push button switch to give the sabre some character. I was all set to properly wire the electronics, but the switch was too deep to fit properly in the tube. The detail on the side is the 90 degree connector from Active electronics.

Total cost: Under $20
Total labour: A weekend
Screen accuracy: N/A Custom

Master Sabre

Once I purchased a rotary tool (Dremel) I tackled a more complex sabre. I wanted very sleek lines on this one. Something that said "I'm so good, I don't need a flashy sabre."

My basic parts list:

Collection of Heat Sinks - from trash at work
Vacuum Cleaner handle - from trash at home
D-Ring assembly - from trash at work
90 degree connector - Active Electronics

Using JB weld, a powerful metal epoxy, I glued a series of scrap heat sinks and connector parts to form an interesting emitter. These were then attached to the end of the chrome tube from a crappy vacuum that I tossed out.

I used some foam tape for grips, as seen here. But no matter how I held it, it still looked like foam tape. I substituted windshield wiper blades, but they were too big and didn't feel right. I eventually settled on using 6 small leather strips made from the remnants of my Jedi belt. It is long and narrow and very elegant, suitable for a more civilized age.

Total cost: Under $10
Total labour: 2 weeks
Screen accuracy: N/A Custom

Jedi Belt

Here are the rules for Jedi belts as far as I can determine:

Belts are wide. 2-3 inches is a good target
Belts are tan/brown or black
Belts have a smaller inset belt
Belts have unique front buckles

Within these rules, there seems to be two styles of Jedi belt in Star Wars. Both Mace Windu and Adi Gallia have a flat buckle on the smaller belt that is fed through two slits in the front. Obi-wan and Anakin have the smaller belt surrounded by rivets. I chose the former as my model.

My wife found a nice wide black belt that would fit my large size. The leather ties in the back make it very adjustable and give a nice flowing feel. I chose the former for my style, so I incorporated the ring motif from the ends of the belt for the buckle. I bought a smaller belt made of thin strip "leather" and three nice sized rings. I cut off the excess rings, and painted the remaining one to give it a rust/brass look. I cut the larger belt and fed the thin belt through. I used a Fix-All style of glue that would work on the "leather." The overall effect is nice and although it is completely personal and unique I think it follows the model nicely.

Total cost: Around $20
Total labour: 1 week
Screen accuracy: On Model

Japor Snippet

I thought making a replica Japor Snippet would be a quick, fun project. It was harder than I thought. I only had one really good picture of it, and it didn't show the depth of the prop. I guessed and made two versions, one very thin and curved, the other stubby and ultimately more accurate. I mixed some Sculpty clay to get a good tan colour, then carved it with the basic clay tools. Getting the overall shape of the piece was the trickiest. The proportions were very important, and it often came out looking like an I-beam. Once carved and baked, I gave it a wash with acrylic paint.

Total cost: Around $5
Total labour: 1 week
Screen accuracy: On Model

Disclaimer: Star Wars is the property of George Lucas and Lucasfilm Inc. This web page is my attempt to share with others my little hobby and attempts at costuming. No profit will be made as a result of this page, so don't sue me, okay? All original pictures are Copyright Kent and Raelyn McKay 2005.