Sith Lightsaber

The design of the Sith Lightsaber needed to express darkness, ruthlessness, yet simplicity.

This image, taken from http://www.swtor-fever.com/sith-empire-class-guides/sith-inquisitor-guide/, was the main inspiration for the Sith Lightsaber. The top left style was the focus of the design.

First sketch.

 Finalized sketch.

Designed in Google Sketch Up.

The claw added the character of ruthlessness. 

The construction of the master was quite simple. Two pieces of PVC pipe sleeved together. KISS!

And the claw? Well, less intimidating in raw form.

This literally took 30 minutes to make!

 1/8" foam was installed for the handle grip.

The claw was sculpted using wood putty and sanded.

The saber was coated with primer and sanded. The claw was installed. And inscriptions using the aurebesh  font were transferred to the master.

Another view of the inscriptions.

The inscriptions were cut into the saber using a dremel tool.

The master all primered and sanded to perfection.

In prop-making, what the master looks like is irrelevant...the shape is the only thing that matters. So, why not use buttons for buttons!

A box enclosure was built to serve as the rigid enclosure for the mold. Clay is used to simulate the bottom half of the mold while the top half is being poured. The dimples serve as registration keys.

And SCIENCE! Mixing the components for the silicone rubber.

And the top half of the mold is complete!

The clay must be completely removed, then the bottom half of the mold can be poured.

Mold without the master inside.

This image shows how the castings will be made. The wooden dowel rod is inserted to create the cavity for the blade to be installed. Note the pronged tee nut at the end of the rod. This will end up being embedded in the plastic and will allow the blade to screw into the saber. The rod is lubricated with petroleum jelly to increase the inner diameter slightly to facilitate removal of the rod.

Preparing to pour the other half of the mold.

The two halves of the mold.

The first casting of the Sith Lightsaber. Just needs to be trimmed and painted. 

Test fitting of the blade. Since this is a film prop, the blade is a 3/4" wooden dowel rod that will be painted florescent red.

First coat of paint.

Second coat of paint.

Final coat of paint.

Finished product.