So there is a really cool website i found called the custom saber shop, and they sell a modular system for making lightsabers. The options are really good, and you can replicate a movie saber, or design your own. It's not an easy project, and there is some basic dc circuit knowledge needed, along with soldering. You could do a lot of machining and fabricating if you had the knowledge and tools (I don't). Right now I just have the lights working. Sound requires a special sound card, and it's the most expensive individual piece to buy, so that will come soon. Once I have the sound board, the blade will also shimmer/flicker and look more like a lightsaber.

Here is a video:










This is the complete list of parts I used for this saber:

1 of: 7" Fluted with standard style switch hole
1 of: Screw on LED blade holder style 12
1 of: Main Body Powder Coating (Wet Black) (DFS2)
1 of: Blade Holder Powder Coating (Wet Black) (B123)
1 of: Drill & Tap Hole (8-32)
1 of: MPS Pommel style 8
1 of: MHS choke style 1 short
1 of: Choke Powder Coating (C1S3)
1 of: MPS Clip
1 of: MPS Insert style 6
1 of: 3.5mm R.I.C.E.â„¢ Port Style 1
1 of: 2.1mm Power Jack
1 of: 16mm Anti Vandal Latching Green Ring Switch
1 of: 16mm Anti Vandal Momentary Green Ring Switch
1 of: 8-32 x .3" black thumb screw
1 of: Rebel Star LED & MHS Heatsink Module
1 of: LED "TCSS style" Show blade 1" OD (38 inches)
3 of: Dual 22 gauge wire (sold by the foot)
8 of: 2 Wire quick connector
2 of: 1/8" Heatshrink tubing (I recommend a lot more, had to buy some at radioshack, and it was way overpriced)
1 of: Box 14 Mounting holes service
1 of: Activation box style 14
1 of: Tamiya to JST charger adapter
6 of: JST connectors
1 of: 4-40 Button Head
1 of: 7.4v Li-ion 800mAh 14500 Battery Pack
1 of: 4.7ohm 5w resistor
1 of: 3.7V-14.8V Li-Ion Smart charger

I ordered more parts, but all of these were used partially or completely in this saber, not to mention the new soldering iron i had to buy because the old one fell of the table and broke the tip off, leaving the threaded end inside the tip. Check out http://www.thecustomsabershop.com and the forums there for more info, feel free to PM me, I will help you as well with what I know.

Dave

And here I had my hopes up that you found a way to make a REAL one, alas though this is pretty sweet in and of itself.

Oh I wouldn't make a real one if I could, I'd totally cut my arms off

Looks nice! How much does something like this cost?

Wow! That is SICK!

Simply the best, better than all the rest.

Sha-Wing!!! I love it!

as Lord Vader once said: I see you have constructed yourself a new lightsaber; your skills are complete