A fully removable chassis core mixing steel and brass for a nice contrast. and featuring for the first time a dual motor install for the Plama Gate and Kyber Crystal!

DIY – ELF-Sabers AS3 (2025) – Master Chassis – Anakin Skywalker

Component List

COMPONENTS LIST:
– ProffieBoard 3.9 x1
– 28mm 4ohm 3W Bass Speaker x1
– High Amp Kill Switch x1
– Brass Tactile Switches (4mm) x2
– MICRO MOTOR 47 RPM x1
– MICRO MOTOR 6400 RPM x1
– Blade Connector – Short Pins x1
– 5mm Crystal Pixel PCB x1
– Large  pixels ring x2
– 5mm pixel strip – 12 LEDs x2
– 5mm pixel strip – 6 LEDs x1
– 3.5mm pixel strip – 10 LEDs x2
– 1.5MM BRASS ROD
2 x 10mm
– 3mm OD Copper Tube
3 x 32.2mm
– 4mm OD Copper Tube
2 x 23.3mm
– OLED Screen x1
– 2mmx2mm Magnets x8
– M1.6 socket screw 4mm length x9
– M1.6 socket screw 5mm length x2
– M1.6 nuts x 11
– M2 socket screw 8mm length x3
– M2 nuts x 3

Introduction

  • Disclaimer

    GOTH-3Designs cannot be held responsible for any mistakes made by DIYers during their install. You must have a good understanding of what you’re doing, of the components used and the safety measures associated to them. Always wear protective gear when working on install (gloves, eye protection, …), GOTH-3Designs cannot be held responsible in case of accident.

  • Note #1

    Always use the smallest wires to make your install easier. There can be big differences between one wire type and another for the same AWG specs. PTFE Wires with the smallest OD are recommended such as those sold at The Saber Armory. A good wire management is also required, routing wires properly helps a lot saving space.

  • Note #2

    These instructions will not cover how to wire the soundboard, make sure to learn how to by reading the manual. We have also typical soundboards wiring available in the Padawan Tutorials. Always test your install along the way! Verifying that everything works after important steps is better than having to dismount everything because something wasn’t wired properly.

  • Note #3

    3D printed parts can have slight size variations which may require some small adjustments by the installer (such as sanding, hole deburring, … etc). Some metal parts could also be slightly bent, but are usually easily bent back in shape. This is all normal and part of the DIY build process.

Note about steel material

  • Steel is printed with a different technology compared to brass parts.
    They come out with a bit rough surface

    They will require additional post processing to look at their best aspect => polishing.
    We use Dremel flat wheel and brush, with a 2 steps polishing process.
    1 – Polishing using Dremel flat wheel

    2 – Brushing the steel to give the outer surface a satin finish

    3 – Also check all steel parts and holes, and bore out if needed.

AS3 Master Chassis DIY Instructions

  • For this install, the main chassis and crystal chamber are first installed separately, and then joined together (bridging each wires).

    Chapter 1 – Main chassis install

    Step 1 – Install the negative battery tab

    Step 2 – Install the kill switch

    Step 3 – Install the speaker

    Note, we use heatshrink tubing to glue the wires inside the chassis for a cleaner install

    Step 4 – Glue the 2 x M1.6 nuts inside the chassis

    Step 5 – Install the 5mm side pixel strips (12 pixels)

    Always test along the way

    Step 6 – Glue the side steel covers

    Step 7 – Glue the magnets and check the brass covers


    Test again

    Step 8 – Install the positive battery tab (new chassis design, the tab slides in from the top – this provides a reverse battery protection)

    Step 9 – The battery cover can be added and secured with the 1.5mmOD rod

    Step 10 – Install the 3.5mm pixel strip

    Step 11 – Manage the wires to keep the install clean

    Step 12 – Install the soundboard

    Step 13 – Install the 5mm 6 pixels strip on top of the soundboard

    Step 14 – Install the OLED screen

    Step 15 – Insert the middle chassis part
    Note: the steel part could need deburring inside to ensure is slides over the OLED screen without scratching it. Make sure to check the inside of that part before assembly.


    Step 16 – Screw the 2 x M1.6 screws

    Step 17 – Manage the switches wires and add the switched holder

    Install the switches, and glue them on the holder

    Complete by adding the switches steel cover

    Chapter 2 – Front Chassis Assembly

    Step 18 – Build the front chassis module
    First, check the front motor assembly

    Then, install and glue the pixel ring and its clear part in front
    Next, glue the spinning part on the motor

    Insert and glue the motor in its slot
    And finally install the blade connector

    And test

    Step 19 – Insert the front chassis assembly into the steel emitter

    Step 20 – Prepare a 5mm hole into the crystal to host the 5mm pixel,

    then install the crystal pixel

    Step 21 – install the 3mmOD tubes and join the crystal chamber (passing the wirtes through the tubes)

    Step 22 – Screw the 6 x M1.6 screws and nuts

    Test

    Step 23 – Glue the 3 x M1.6 screws into the plama gate

    Step 24 – Manage the wires coming from the crystal camber, and install the 4mmOD Tubes

    Step 25 – Install the plasma gate clear part, and then add the 21mm motor

    Step 26 – Join the plasma gate to the crystal chamber

    Test the motor and screw the plasma gate

    Step 27 – Install the 2nd pixel ring

    Chapter 3 – Joining both halves

    Step 28 – Manage and bridge the wires

    Test

    Step 29 – Secure the assembly
    – Add the 3 x M2 nuts into their slots
    – Glue the chassis on the 4mmOD tubes side to ensure no gap appears after screwing the screws.
    – screw the 3 x M2 screws (do not overtighten)

    Done