Luke ANH Sabre: Shaft

Introduction - Parts - Shaft - Emitter - Details - Assembly

Cut the flange off the 12" chrome tail piece.

Draw with permanent marker shape of ‘S’ cowl for the emitter end. Use the Dremel to roughly cut out shape then use the grinding tip to accurately cut to the line you have drawn. Once you are happy with the shape use stone tip to remove any burrs and smooth the end.

Measure approximately 6/10" down from the tip of the emitter end of the tube and draw a rectangle approx 4/10" by 7/10". Cut out using the Dremel cutting disk and then extend the length of the rectangle to allow the assembly of emitter in the tube. Using pliers bend the emitter holders out to 90o and then finish the resulting hole and supports to remove burrs.

Mark the position of the small square hole above the emitter holder hole. Drill with a small bit and then use a square rat’s tail file to make your circle a square.

Mark the position of the holes for the recharge sockets. Using a hammer and punch tap the center of these holes and then drill ½" holes to accommodate the sockets.

Mark the position of the two small rectangles above the eye. Drill these out and then finish with a flat rat’s tail file.

Mark the position of the screw above the eye. Drill a hole to accommodate.

Cut a small section off a black shampoo tube in preparation to ‘cap’ the emitter end. I drilled a hole in the center of this cap and set a brass washer there to represent the hole through which the blade projected.

Print out the pattern for the D-ring assembly 1:1 from the blueprint. Trace it on to a piece of the flat Z aluminum stock. Cut out with tin snips then file to the correct shape. Bend around the D-ring and drill the mounting holes.

Take a fender washer. Do not use stainless steel washers as I did as it is way to hard to work with. File a little off the circumference of the washer until it tightly fits into the end off your tube.

Take a little scrap metal a drill 2 holes in it to mirror your D-ring assembly. Make a sandwich of the D-ring assembly, the fender washer and your scrap. Screw together with 2 small nuts and bolts as shown.

Take one of the chrome extension tubes and measure 1 inch in on the wide end. Cut this off and finish with the Dremel until you have what appears to be a chrome napkin ring. Repeat with the other extension.

Take the key stock and cut two 1 inch lengths. File the ends smooth.

Remove the bubble display from the calculator. Mine was the 9 bubble variety with raised ridges top and bottom. I simply cut a piece of foil tape and applied it to the display to cover everything but the bubble display.

The activation lever was cut from part of an old, metal, windshield wiper holder. This was then dremelled and bent into shape and the black paint sanded off.

Cut a 1 inch strip of foil tape. I scored this repeatedly with a blunt letter opener to get the cross hatched effect. This will go around the 2 clamp pieces when it comes to assembly