Other Chassis for Ben Solo

PP Ben Solo Chassis

Parts Details:

1- 3D printed Chassis parts:

Shapeways Shop Section ⇒ C4 – Phoenix Props

Two chassis levels are available for Phoenix Props Kylo:
Both these chassis have the “MultiBoards Adaptive Chassis 3.0”  design which allows any major recent soundboards to be installed (Plecter Labs or NEC). ProffieBoard can be also installed using this adapter.


Multi parts advanced design, the cover plates are printable in metal for the best reveal appearance. The Crystal Chamber opens the give access to the soundboard SD card. It also uses a big 26650 battery for the best run-time.
Prices: Depends on the materials selected and Shapeways current rate. Build your cart using the links below in order to get a price estimate for the full chassis.
Install Level: Advanced
 Part 1 – Main Chassisben-solo-pp-master-chassis-part1
 Part 2 – Cover plate 1
Part 3 – Cover plate 2
 Part 4 – CC 1ben-solo-pp-master-chassis-part4
 Part 5 – CC 2ben-solo-pp-master-chassis-part5
 Part 6 – CC 3ben-solo-pp-master-chassis-part6
 Part 7 – CC 4ben-solo-pp-master-chassis-part7 
⇒ Part 8 
– Crystal (optional): ben-solo-pp-master-chassis-part8


Advanced and detailed design including covers for the 2.1mm recharge port, 28mm speaker and 26650 battery. A kill key is also included.
Depends on the materials selected and Shapeways current rate. Build your cart using the links below in order to get a price estimate for the full chassis.
Install Level: Beginner
 Main chassis (recommended in black plastic): ben-solo-pp-padawan-lightsaber-chassis

2- 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!
For the Padawan and Master chassis:
 1.5mm OD Brass rods: Padawan 4 x 36mm, Master 2 x 39.8mm + 2 x 116mm

3- DIY empty hilts:

 Contact Phoenix Props

4– Electronic components and blades:
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:
Plecter Labs – from the entry level Nano Biscotte to the high end Crystal Focus.
Naigon Elelctronic Creations – from the entry level Spark 2 to the high end I2.
ProffieBoard can be also installed using this adapter.
Battery, 26650 3.7v battery
⇒ Recharge Port, 2.1mm port is used on this chassis (kill key included in the chassis kit).
 Battery charger, according to the battery voltage used.
 Main Led, Tri-Cree XPE-2 or Neopixel
 Switches, tactile switches are included with the hilt
 Speaker, 28mm Speaker, bass or flat
 Accent Leds, 5mm for the crystal chamber, 3mm for other accent leds.
 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 solder joints.
 1″ OD blade or 7/8″ OD blade (with adapter).


Check out this demo from OxR Creations:

Quick Install Guide: 

– 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.

Note 1:Use small wires to make your install easier
=> for Tri-cree install 30awg for main wires and 32awg  for accent leds and switches are highly recommended
=> for Neopixel 24awg PTFE for main wires (battery and led strip + and -), and 32awg  for accent leds and switches are highly recommended

Note 2: These instructions will not cover how to wire the soundboard, make sure to learn how to by reading the manual. make sure to test your install along the way! Making sure everything works after important steps is better than having to dismount everything cause something wasn’t wired properly.

Note 3: Recharge port wiring reminder:



The install is pretty straight forward.

First, the 2 main chassis part need to be joined and glued together. Four 1.5mmOD  are used to support and give strength to the assembly.
The recharge port is installed at the end of the chassis, with a cover to be glued to hide it.
There is a dedicated channel for the wires to pass around the 28mm speaker. Once the speaker inserted, there is a cover as well to be glued. Finally, the battery slot also has a cover to be glued.

The led module or neopixel connector needs to be secured in the emitter part using a retention screw.
Once the led module and the switches are installed in the emitter part, then wired to the soundboard, the chassis can be inserted and will need to be secured by retention screws as well.


This quick install guide has been created with a prototype chassis in plastic. Some small details have been modified on the final version but the overall procedure remains the same.

Cut the rods, the short ones go on top, the long ones on the bottom. There should be no gap between the upper chassis, the crystal chamber doors, and the crystal chamber shell, as shown below:

Once fitment tests are done, glue the rods on the upper chassis part

Install the led or neopixel connector

Install the switches

Install the soundboard

Once all wires are soldered on the soundboard, insert the upper chassis part into the emitter and secure it with 2 retention screws on each side (tap to be done on the holes).

Wire sleeves are used to pass the wires through the crystal chamber.

Glue 3mmx2mm magnets in the crystal chamber doors dedicated slot as shown below

Glue the CC insert into the CC shell, and wire the 5mm crystal led. Do not glue the crystal, it is supposed to be removable.
Slide in the CC shell and insert assembly

Add the 26650 battery, there is a channel for the wires to pass under the speaker.

Insert the speaker, and glue the cover over it.
Add the 2.1mm recharge port and secure it with its hex nut, then glue the cover over it.

Add the top chassis cover, inserting the back first.

Assemble both upper part and bottom part, glue the rods to the bottom part to secure the assembly.

Once all wires are connected, add the bottom cover part.

Access to recharge port is allowed by removing the pommel. Access to the SD card is allowed by opening the CC doors and removing the crystal.

Modding the bottom part of the hilt to allow easy reveal (twist lock):