Index:

=> Parts Details
=> Installation Instructions


Parts Details: 

1- Hilt / GRAFLEX 89Sabers Kit:

 Available on The Saber Armory.

2- 3D printed Chassis parts:

Shapeways Shop Section ⇒ C1-4 – Graflex 89Sabers
PadawanVariant 1Available
PadawanVariant 2 – Available

Important note:
It is possible to use any of Graflex Vintage Chassis into the 89 Graflex by performing some simple modifications to the inner core. Check instructions below for more information.

Variant 1:
A simple to install and budget all.in.one chassis, mainly dedicated to secure the electronic.

Prices: Approx $50
Install Level: Beginner
All.In.One: graflex-89sabers-padawan-var1-lightsaber-chassis
Sounboard Cover (optional)graflex-89sabers-padawan-cover-optional

Variant 2:
Simple chassis with a removable battery holder slot (Keystone 18650 holder)

Prices: From $50
Install Level:  Beginner
All.In.One: graflex-89sabers-padawan-var2-lightsaber-chassis
Sounboard Cover (optional)graflex-89sabers-padawan-cover-optional

 

3- Additional chassis parts:

Most of the chassis parts needed for our chassis are available at The Saber Armory.
Local hobby stores or online store (as well as eBay) are a good source for parts.
You can also be inventive and add any custom parts, wire mesh, paint job or else to your chassis to give it an unique look!
Padawan Chassis:
chassis 6-32 retention screw (a hole will need to be drilled on the chassis to face the 6-32 retention screw hole present on the core).

4- Electronic components and blade:

Saber electronic components are basically more or less similar from one saber to another. You’ll need a main Led, a Battery, a recharge port, one or two switches, a soundboard, accent leds, a speaker and wires. Then the blade is the last part of your saber, they are usually made from PolyCarbonate tubes + tip.
You can find most of what you’ll need at The Saber Armory. Some components can also be found at The Saber Bay on Etsy. Local electronic shops or online stores like Digikey are also a good source.
Soundboard, the “heart” of our sabers is the Soundboard, here are the 2 major Soundboard producers:
Plecter Labs – from the entry level Nano Biscotte to the high end Crystal Focus.
Naigon Elelctronic Creations – from the entry level Spark to the high end I3.
Battery,
Padawan Var1 – Single 18650 3.7v battery or 2×18500 7.4v pack
Padawan Var2 – Single 18650 3.7v battery
⇒ Recharge Port,
Padawan Var1 – 2.1mm recharge port (kill key included)
Padawan Var2 – Not used
 Battery charger, according to the battery voltage used.
 Main Led, Tri-Cree XPE-2 or Neopixel.
⇒ Heatsink / led module or Neopixel pogo-pin connector holder, 1″
 Switches, tactile switch for the main red button switch.
 Speaker, 28mm speaker (bass or flat)
 Accent Leds, 5mm led for the Crystal Chamber recommended (if RGB, read your soundboard manual to select between common anode or common cathode led), 3mm leds for the others.
 Wires, we strongly recommend PTFE wires, as the insulation is thin while still able to handle current very well. You can find them from this eBay shop for example. Use the smallest AWG size possible:
– Tri-Cree install => 30awg for eveything
– Neopixel install => 32 awg wires for everything except Battery and Neopixel strip + and – (24awg PTFE).
 Heat shrink tubing, to protect your joints.
 7/8″ OD Blades (with 1″ adapter) or 1″ OD blades.

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DIY Instructions:

Disclainer:
– These instructions will details the install procedure as much as possible. GOTH-3Designs cannot be held responsible for any mistakes made by DIYers.
– Always wear protective gear when working on install (gloves, eye protection, …), GOTH-3Designs cannot be held responsible in case of accident.
– These instructions will details the install as much as possible. GOTH-3Designs cannot be  held responsible for any mistakes made by DIYers. Read the full instructions before starting your install. Commission an installer to build the hilt for you, if you feel unsure about what to do.

Note 1: Recharge Port wiring reminder

Note 2: MutliBoards Adaptive Chassis
Soundboards are installed with the SD card facing down.
Adapters for ProffieBoard are also available.

Hilt modification for Vintage Chassis install.

To make this mod easier, purchase the drill template here.
89Sabers Gralfex - Blade Holder drill template in White Natural Versatile Plastic
Unscrew the lip, and all other screws, brass pins, …

Remove the blade holder by sliding it down.

Unscrew the bottom blade holder part, it will not be used anymore.
Then unscrew the slide switch PCB and set it aside for later use.

Using a Dremel, cut the thread area away from the blade holder, as shown below (to be down slowly/carefully in order to keep the remaining area flat).

Sand the bottom if necessary to have the bottom as flat and smooth as possible.

Use the drill template to locate exactly where to drill and tap two 4-40 threaded holes.
In order to align the chassis perfectly with the Graflex hilt, make one of the hole face the red button wires channel, then mark the two other holes.

We start with a small drill bit and a drill press (Dremel) in order to pre-drill the two holes, and then double check the correct alignement with the template again.

Then we use the 4-40 drill bit to obtain the correct hole size. Make sure both holes have the same depth to easy the threaded rods length calculation.

Tap the holes. To be done slowly, without too much force and with repeatedly extracting material by unscrewing the bit.

Check that the 4-40 threaded rods screw in perfectly.

Install the slide switch PCB back.

The Vintage/ Replica chassis can now be installed normally.

Follow with the Vintage/Replica chassis install instructions here.

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