Other Chassis for Vader DV6

Tutorial for ELF-Sabers DV6 (2023) Master Chassis

An imposing Master Chassis worthy of Lord Vader!
It a fully removable core, featuring a double crystal chamber and an overall design inspired by Darth Vader.

Concept

Other Parts Details

Magnets
– 2mmx1mm NeoDymium Magnets x 8
– 2mmx2mm NeoDymium Magnets x 18
Tubes and Rods
– 1.5mmOD rods x 3 with 107 length
– 1.5mmOD rods x 3 with 86.2 length
– 1.5mmOD rods x 2 with 35 length
– 3mmOD tubes x 2 with 18.3mm length
– 4mmOD tubes x 2 with 40.7 length
– 4mmOD tubes x 2 with 38mm length
– 4-40 threaded rods x 2 with 60.3mm length

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 very slight accuracy variations. In some rare cases, some sanding or hole deburring can be required. Additionally, metal parts can arrive a bit bent, but are normally easy to bend back into shape. Consult the FAQ if you encounter issues with parts that cannot be solved easily.

Note on chassis cost

  • This chassis is big and heavy, the cost in full metal (like Brass) is thus rather high. Always remember that all parts are also available in high quality nylon plastic, which allow to lower the overall chassis cost. Here is an example and MJF black plastic / natural brass mix that retain the really nice chassis look while being significantly cheaper.

Quick Install Guide

  • Coming soon – work in progress

    Step 1 – Wire and install (glue) the single pixel in its slot.

    Step 2 – Wire and install (glue) the speaker in its slot.

    Step 3 – Wire and install (glue) the kill switch in its slot.

    Step 4 – A 2020 pixel strip can be added here for extra effects  

    Step 5 – Insert and glue the CC insert, respecting the correct orientation as shown. All wires pass at the center, and then on the side.
     

    Step 6 – Install the single pixel and the crystal

    Step 7 – Insert the cover over the speaker / CC assembly

    Step 8 – Add the 3mmOD, 4mmOD tubes, and 4-40 threaded rods where shown

    Step 9 – Screw the nuts on the 4-40 threaded rods.

    Step 10 – Add the CC side insert and the three longest 1.5mmOD rods

    Step 11 – Add the other side CC part and secure it with the 2 remaining nuts on the 4-40 threaded rods.
    Also add the three shortest 1.5mmOD rods

    Step 12 – Add the second CC insert and crystal, with its single pixel installed

    Step 13 – Install the Switches PCB and the two 4mmOD tubes (that serve as wires channel)

    Step 14 – Install the battery tabs

    Step 15 – Glue the magnets on the chassis and battery covers

    Step 16 – Add the battery covers and switches PCB cover, the join the assembly

    Step 17 – Install the soundboard
       

    Step 18 – Insert the front chassis part, and then glue the two short 1.5mmOD rods

    Step 19 – Glue the magnets on the soundboard cover and chassis

    Step 20 – Finish by installing the NPXL Connector