DIY Instruction for Saberbay’s Darksaber

  • Here are the DIY instructions with Step by Step guide to build this Saberbay’s Darksaber kit.
    The chassis was originally designed by Shtok Custom Works, and GOTh-3Designs stepped in to finish the project with a removable Crystal Chamber part.

Demo

Components

– Soundboard: CFX or Proffie
– Speaker: 28mm Bass Speaker
– Battery: Battery contacts for removable 10650 battery
– Accent Led: Single 5050 pixel, 2020 pixel strip (optional)
– Crystal Chamber Magnets: 8 x 2mmx2mm magnets
– Other: OLED Screen (KR)

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

    These instructions have been created using a prototype hilt and chassis. The production hilt finish is different.

Install Guide

  • Step 1 – Separate chassis parts
    The chassis has 3 parts joined with sprues. First, cut the part shown below using a sharp knife,  following the red lines. Clean the sprues after cutting.

    Next, separate the 2 parts as shown below. One is the CFX to Proffie adapter, the other is the NPXL PCB holder.

    Step 2 – Install the speaker
    Wire and glue the speaker in its slot

    Step 3 – Install the negative battery tab
    Wire and insert the neg battery tab in its slot.

    Then use a heatshrink tube to manage the wires properly (glue the tube in the channel).

    Step 4 – install the positive battery tab and kill switch
    Wire the kill switch and battery tab as shown (2 x  22awg wires on the battery tab, one for the kill switch, the other to feed the NPXL PCB)

    Glue the positive battery tab in its slot

    Make the short wire exit from the kill switch slot and solder it on the kill switch.

    Insert and glue the kill switch in its slot.

    Step 5 – Install the OLED screen
    Wire and glue the OLED screen in its slot.

    Step 6 – Install the NPXL PCB holder
    Wire the accent single 5050 pixel.
    Note: for this example of Proffie install, to limit the number of wires, we use 1 data line and will define the crystal as a sub blade.

    Glue the single pixel in its slot as shown

    Wire the NPXL pogo pin PCB and glue it in its slot, ensuring it is well flush.

    Insert the NPXL holder in the emitter, again ensuring it is well flush.

    Manage the wires to gain space.

    Step 7 – Install the soundboard
    Wire the soundboard and plan the wires for the switches PCB (make sure to use small gauge wires for the switches PCB – 30awg).


    Optional: install a 2020 strip over the board
    Proffie install: glue the adapter as shown

    Test the install, then glue the soundboard in its slot.

    Step 8 – Install the magnets and the Crystal Chamber
    Glue the crystal in the chamber.
    Glue the 12 magnets on the CC part and chassis, ensuring polarities are respected.
    Note: 3D printing can variate slightly and the magnets holes could result either a bit too tight or too loose. If too tight, use a 2mm drill bit to expand them, if too loose, hold the magnets in place until the glue dries.

    Optional: use Aluminum Black to darken the hilt aluminum around the CC.

    Optional: weather the CC part with Brass Black

    Step 9 – Install the switches PCB
    Wire and insert the PCB in its slot.

    Glue the Switch Box magnets (provided with the hilt)

    Step 10 – Install the blade plug and blade
    Insert and wire the NPXL strip, then wire and insert the blade side PCB in its slot.
     
    Insert the plugs and blade into the hilt stem.
    Notes: both plugs and blade will require sanding in order to press fit into the hilt stem.

    DONE!