Plexiglass Energy Sword

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MoeSizzlac

RMO
405th Regiment Officer
One of my projects I wanted to make for my Master Chief was the energy sword seen below.

Spartan with Sword.jpg

I started with plexiglass from homedepot and traced out a pattern of a blade.

20150127_105758.jpg

Next I made several plexiglass rectangles the same size as the template, bolted them all together, and used a ban sawed to cut all the templates out as one whole piece.

20150127_105812.jpg

Next step, I etched out lightning in the middle piece using a dremel. I then glued all the pieces together using a plexiglass acrylic glue offsetting the first and last piece to leave a channel for LED lights. LED lights were from Homedepot but not as expensive as the link in the store.

20150127_105826.jpg

After the glue made everything solid, I used a router (like what you would use on wood) to give an edge to the outside of the blades.

Next step, I need a handle. I took a 1" pvc pipe:

20150127_105857.jpg

and heated with a heat gun it until I could shape it into an oval. I had it in a vise grip to keep pressure on it.

20150127_105917.jpg

Next step was to cut that handle down the center and notch the ends for the blades. I then epoxied the LED lights into the channels.

20150127_161304.jpg

I finished off filling the channels with hot glue.

Next, I had an old battered Force FX lightsaber like this one:
Force%20FX%20Lightsaber.jpg


I wanted to use the sound fx from the prop so I took it apart and positioned the chip and speaker into the handle. I drilled out holes on the handle for a switch from radioshack . The LED lights from Home Depot is a multicolor one (red, green and blue). In other words, the LED has 4 wires, 3 for lights and one for return (negative hookup.) Disregarding the Red light all together, I set up the connections to use the green and blue lights to get my desired color. Next step, Layout all the electronics:
20150128_233749.jpg

Time to hot glue electronics in place and solder/organize all wires:

20150201_102411.jpg

[not pictured] I added a metal bar from sword tip to tip to stabilize the end. Otherwise, it would wiggle back and forth while you handled it and I didn't trust it.

Next, secure the cover, and light it up:

20150129_004122.jpg

20150129_004138.jpg
And here's what it sounds like:

[video]http://www.moesizzlac.com/Videos/20150129_084013.mp4[/video]

Handle is wrapped with a Carbon fiber contact paper. You can pick it up on Amazon. The final look of the handle is on the back of my suit. It looks great lit up in a dark room.

DSC02049.JPG

And that's all for now. Enjoy! Comments and critiques are always welcome.
 

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One of my projects I wanted to make for my Master Chief was the energy sword seen below.

View attachment 16827

I started with plexiglass from homedepot and traced out a pattern of a blade.

[url]http://www.moesizzlac.com/assets/images/Camera%20Phone%20pics/Halo%20Energy%20Sword/20150127_105758.jpg[/URL]

Next I made several plexiglass rectangles the same size as the template, bolted them all together, and used a ban sawed to cut all the templates out as one whole piece.

[url]http://www.moesizzlac.com/assets/images/Camera%20Phone%20pics/Halo%20Energy%20Sword/20150127_105812.jpg[/URL]

Next step, I etched out lightning in the middle piece using a dremel. I then glued all the pieces together using a plexiglass acrylic glue offsetting the first and last piece to leave a channel for LED lights. LED lights were from Homedepot but not as expensive as the link in the store.

[url]http://www.moesizzlac.com/assets/images/Camera%20Phone%20pics/Halo%20Energy%20Sword/20150127_105826.jpg[/URL]

After the glue made everything solid, I used a router (like what you would use on wood) to give an edge to the outside of the blades.

Next step, I need a handle. I took a 1" pvc pipe:

[url]http://www.moesizzlac.com/assets/images/Camera%20Phone%20pics/Halo%20Energy%20Sword/20150127_105857.jpg[/URL]

and heated with a heat gun it until I could shape it into an oval. I had it in a vise grip to keep pressure on it.

[url]http://www.moesizzlac.com/assets/images/Camera%20Phone%20pics/Halo%20Energy%20Sword/20150127_105917.jpg[/URL]

Next step was to cut that handle down the center and notch the ends for the blades. I then epoxied the LED lights into the channels.

[url]http://www.moesizzlac.com/assets/images/Camera%20Phone%20pics/Halo%20Energy%20Sword/20150127_161304.jpg[/URL]

I finished off filling the channels with hot glue.

Next, I had an old battered Force FX lightsaber like this one:
http://www.moesizzlac.com/assets/images/Camera Phone pics/Halo Energy Sword/Force FX Lightsaber.jpg

I wanted to use the sound fx from the prop so I took it apart and positioned the chip and speaker into the handle. I drilled out holes on the handle for a switch from radioshack . The LED lights from Home Depot is a multicolor one (red, green and blue). In other words, the LED has 4 wires, 3 for lights and one for return (negative hookup.) Disregarding the Red light all together, I set up the connections to use the green and blue lights to get my desired color. Next step, Layout all the electronics:
[url]http://www.moesizzlac.com/assets/images/Camera%20Phone%20pics/Halo%20Energy%20Sword/20150128_233749.jpg[/URL]

Time to hot glue electronics in place and solder/organize all wires:

[url]http://www.moesizzlac.com/assets/images/Camera%20Phone%20pics/Halo%20Energy%20Sword/20150201_102411.jpg[/URL]

[not pictured] I added a metal bar from sword tip to tip to stabilize the end. Otherwise, it would wiggle back and forth while you handled it and I didn't trust it.

Next, secure the cover, and light it up:

[url]http://www.moesizzlac.com/assets/images/Camera%20Phone%20pics/Halo%20Energy%20Sword/20150129_004122.jpg[/URL]

[url]http://www.moesizzlac.com/assets/images/Camera%20Phone%20pics/Halo%20Energy%20Sword/20150129_004138.jpg[/URL]
And here's what it sounds like:

http://www.moesizzlac.com/Videos/20150129_084013.mp4

Handle is wrapped with a Carbon fiber contact paper. You can pick it up on Amazon. The final look of the handle is on the back of my suit. It looks great lit up in a dark room.

View attachment 16828

And that's all for now. Enjoy! Comments and critiques are always welcome.

This build is awesome! I wish i had the resources to make such a quality energy sword. Your work is impressive.
 
This build is awesome! I wish i had the resources to make such a quality energy sword. Your work is impressive.

Thanks! It wasn't too long of a build (I mean compared to the suit that is).

So. Very. Cool.
Awesome job Spartan!

Able and willing.

Love the lightning. This might be my next project.

Thank you kindly. Yes, I'd love to see someone build onto this idea. I saw someone do a 3D model of the grip and thought "If I had that, this would be so much more impressive."
 
Wow, great design~! Looks good for the camera, and is solid enough not to break the first time you bang into a door frame. Kudos!!
 
Fantastic! I'd love to be able to create something like this and the final product really looks amazing!
I like the thought of using the sound chip in there as well. I wish these things were solid enough to make without some kind of support between the blades at the end, but you managed to pull it off really well regardless.
 
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