How it's done:
- Cut the blade holder from the soundboardhousing (best with a circular saw or a dremel)
Foto 01 and
Foto 02
- Cut the chrome-plated pipe to 7,5 cm
Foto 03
- Cut the aluminium-tube exactly hat 2,5 cm. This is used as an extra heat sink and as holder
for the Luxeon LED, the lens and the lens-holder.
And it is used as bladesocket. So the blade cannot push the LED into the grip.
Foto 04
- Wrap the aluminium-tube with tape, so it is pressed into the chrome-plated pipe and is flush with it
- Drill three holes with a size of 1 mm through both tubes to screw them together later.
Foto 05
- Glue the lens-holder on the hold points with the Luxeon, after both wires (plus and minus)
are soldered and are connected to the main-wire later
So everything gets more robust and the lens-holder can't be disconnected from the Luxeon and
slip into the blade-holder or the blade.
Foto 06
- Push the Luxeon with lens-holder into the 2,5 cm long aluminium-tube till the lens is flush
with the tube. It's important that the lens-holder is pressed into the tube.
If the lens-holder doesn't fit exactly, you can sand the border a little bit.
Foto 07 and
Foto 08
- Move the brown tube over the chrome-plated tube, so it is in flush with it on the end
- Mark the notch on the top of the winding of the brown tube and drill a 2 mm wide hole into the chrome-tube.
Foto 09 Prepare a steelbolt wo fix
both tubes (it must not get on the inside of the tube), so it cannot move if the blade is turned in.
Foto 10 and
Foto 11
- Now the little 2,5 cm aluminium-tube is screwed with the chrome-tube with three little screws.
The screws should be long enough to fix
the heat sink. So it can't get disconnected in the aluminium-tube and stabilizes the whole thing
Foto 12,
Foto 13 and
Foto 14.
- Now you can solder the Luxeon with the soundboard and isolate it. Plus is the brown wire, minus all others.
Look at Foto 14
- Push the wire into the housing of the soundboard and assemble everything in the hilt. The board
holds without extra screws, because it is fixed through the battery-pack.
- Assemble everything and screw the emitter. Now ca. 2 cm of the chrome-plated tube sould be
outside of the emitter and you have a blade-holder with 5 cm or more.
Foto 15 and
Foto 16.
Because the diameter of the blade is a little smaller than the inner-diameter of the tube
(blade holder), you have to wrap the blade
with tape until you have to press them into it. So you save an extra screw which fixes the blade.
Foto 17
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Das Lichtschwert
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