(Flash)Light saber

Release your inner Jedi (or Sith) by building your own light saber - from a mini LED flashlight!

Parts

• Mini LED flashlight - https://smile.amazon.com/dp/B01CTX742M?psc=1&ref=ppx_yo2ov_dt_b_product_details
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• 3D printed hilt cap - 3 designs to choose from
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• 3D printed coupler - 5 designs to choose from
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• Clear plastic cover/guard/protector for a T8 (1") bulb, cut to desired length
• 3D printed clear cap
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• Colored tissue paper
• Washi tape for friction fitting (optional)
• Aluminum tape for cap (optional)

Print Instructions & Special Considerations

• Coupler - 3 walls, infill doesn't matter. 
  • Inner diameter for tube side is 31.05mm.
  • Inner diameter for flashlight side is 21.1mm.  
  • It's better to go looser than too tight as you can use tape to build it up to friction fit.
• Hilt Cap
  • The hilt cap moves so that you can press the button on the bottom of the flashlight.  Clearance between the pieces is 0.3mm.
• Cap
  • Use a transparent filament such as PETG
  • 0% infill
  • 8 top layers to ensure top is covered

Assembly Instructions

1. Print a coupler, hilt cap, and top cap.
2. Prepare the flashlight
   • Open the flashlight battery compartment to remove the plastic battery long-term storage shield (if present).
   • Remove the lanyard from the flashlight (if present).
3. Fit the coupler on the top of the flashlight.  
   • Build up the flashlight rim with washi tape to make a friction fit.
4. Fit the hilt cap to the bottom of the flashlight.
   • Build up the flashlight rim with washi tape to make a friction fit.
5. Cut the clear T8 bulb tube to the desired length.
6. Cover the bottom of the transparent cap with either aluminum tape (for better reflectivity of light) or colored tissue paper for light diffusion.
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7. Fit the cap into the clear plastic tube and glue if necessary. 
8. Cut tissue paper about 4-5" wide of the desired color for the blade.
9. Roll the tissue paper up around a helper rod then feed it into the clear plastic tube.  Cut the paper to length. 
   • 
10. Fit the clear plastic tube into the coupler.
    • Build up the tube with washi tape to make a friction fit.
11. [Optional] Using a pin, melt a small hole in the hilt cap and re-attach the lanyard.

You're done!  Brandish your new laser sword like the badass Force wielder that you are.