_FBgiantLS

There’s not a whole lot to say here… I mean, they’re GIANT LIGHTSABERS!!

Why, you might ask, would someone make these? WHY NOT?!    Actually, the truth is, a company asked me to make an over the top Star Wars/Christmas themed display, and these were a part of it.  Fortunately, I made a video of the build so I could share with you guys!

 

They are absolutely ridiculous, but they were one of the most fun projects, and videos, I’ve made in a long time.  I think I might need to spend a little more time with projects that are just senseless fun!

Enjoy!

Here’s what you’ll need:

(purchasing via these affiliate links supports ILTMS)

I gathered some spray paint and black duct tape for decorating.

Screen-Shot-2015-11-12-at-9.50.11-AM

For the handles, I got two 12″ concrete forms.

Screen-Shot-2015-11-12-at-9.50.23-AM

One can of spray paint was more than enough to fully cover both tubes with paint.

Screen-Shot-2015-11-12-at-9.50.35-AM

The “blades” were made from a single sheet of corrugated plastic sheeting.

Screen-Shot-2015-11-12-at-9.51.22-AM

I wrapped them into a tube, and clamped the ends. I predrilled holes along the edge where they overlapped.

Screen-Shot-2015-11-12-at-9.51.48-AM

I drove in some sheet metal screws to hold the tube space.

Screen-Shot-2015-11-12-at-9.51.58-AM

Once the paint was dry, I used black duct tape to decorate the handles.

Screen-Shot-2015-11-12-at-9.52.20-AM

I found that it was easiest to get a straight line by rolling the handle on a table.

Screen-Shot-2015-11-12-at-9.52.34-AM

It’s really easy to make these resemble lightsaber handles with just tape.

Screen-Shot-2015-11-12-at-9.52.53-AM

I made a circular paint mask by tracing the duct tape roll onto some scrap cardboard.

Screen-Shot-2015-11-12-at-9.53.19-AM

I cut out the circle with a utility knife.

Screen-Shot-2015-11-12-at-9.53.34-AM

Using blue tape, I mounted the mask to the handles.

Screen-Shot-2015-11-12-at-9.53.44-AM

A light coat of red spray paint added a big on/off button.

Screen-Shot-2015-11-12-at-9.54.11-AM


For each handle, I cut two 12″ length of 2×4.

Screen-Shot-2015-11-12-at-10.00.23-AM

On the table saw, I ripped these down into 1 1/2″ strips.

Screen-Shot-2015-11-12-at-10.00.51-AM

I also cut some MDF scraps to 12″ long.

Screen-Shot-2015-11-12-at-10.00.59-AM

I put a short bit into my driver, so it would fit inside the “blade” tube.

Screen-Shot-2015-11-12-at-10.01.13-AM

I drove some drywall screws through the plastic, from the inside.

Screen-Shot-2015-11-12-at-10.01.30-AM

These screws attached four 2×4 pieces to the outside of the tube, evenly spaced around it.

Screen-Shot-2015-11-12-at-10.02.24-AM

I removed the bracket from an LED spotlight.

Screen-Shot-2015-11-12-at-10.04.20-AM

I screwed the bracket into the center of the MDF scraps I’d cut earlier.

Screen-Shot-2015-11-12-at-10.04.30-AM

Then I reattached the spotlight to the bracket.

Screen-Shot-2015-11-12-at-10.04.41-AM

The spotlight is adjustable on the bracket, so I faced it straight up.

Screen-Shot-2015-11-12-at-10.04.59-AM

Then I screwed the MDF into the bottom of two opposing 2×4 pieces.

Screen-Shot-2015-11-12-at-10.05.10-AM

The entire blade assembly fit into the handle tube. I slid it in until the 2×4’s were completely hidden.

Screen-Shot-2015-11-12-at-10.05.25-AM

I drove drywall screws through the outside, into the 2×4 using 2″ screws.  Each 2×4 got at least two screws.

Screen-Shot-2015-11-12-at-10.05.33-AM

The lightsabers are way more rigid than I expected.. in fact, you can fight with them 🙂

Screen-Shot-2015-11-12-at-10.05.54-AM

Watch the video above to see them in action!

Screen-Shot-2015-11-12-at-10.06.48-AM

  • Pingback: Maker Digest 11 - The Geek Pub()

  • Pingback: VIDEO: Star Wars fan creates giant lightsaber | Entire News Link()

  • Pingback: VIDEO: Star Wars fan creates giant lightsaber | IT Aid Centre()

  • Pingback: VIDEO: Star Wars fan creates big lightsaber | NewsTerm()

  • Pingback: VIDEO: Star Wars fan creates big lightsaber | NewsTerm()

  • Kevin Moore

    Hi Bob! Love your ideas. I saw the saber video yesterday and suddenly felt sick at work. … Or was I sick of work and really wanted to build these with my kids. I ditched the office and stopped at HD on the way home to gather supplies. A few hours later and “insert saber sound” I’m finished. They look awesome. However I want them brighter, mine don’t seem to be as bright as yours. I used the same clear corrugated roofing and a LED 400 lumens flood light( perhaps I need a spot light instead of a flood light). Color is 4000 and has a interchangeable red and green lens caps. Do you think if I frost the tube lightly with white spray paint it would help?

    • Jason

      I think I tried the same flood light you did. I frosted the tube, and it made a huge difference. However, the kids and I decided to try looping Rope lights through the core of the tube. The neighborhood response has been pretty epic.
      We still have some more work to do on the decorations, but my son and I stayed up last night making sure the light sabers were up before tonight.
      Bob, I love your channel on Youtube, and will leave it on while I am working in the office. Thanks for the inspiration. I hope you and the family enjoy Star Wars! We are taking the night off from projects to see it tonight.

    • Jason

      I think I tried the same flood light you did. I frosted the tube, and it made a huge difference. However, the kids and I decided to try looping Rope lights through the core of the tube. The neighborhood response has been pretty epic.
      We still have some more work to do on the decorations, but my son and I stayed up last night making sure the light sabers were up before tonight.
      Bob, I love your channel on Youtube, and will leave it on while I am working in the office. Thanks for the inspiration. I hope you and the family enjoy Star Wars! We are taking the night off from projects to see it tonight.

    • [left this on YouTube as well, but just in case]

      Sorry you were feeling so bad 😉 Frosting would definitely help some, but instead of spraying white, I would lightly run over the whole surface (which will take a while… why I didn’t do it) with some sand paper. Other people have suggested putting a reflective cap on the end (maybe with aluminum foil) to reflect the light back down into the tube.

  • Randyman

    My son is a big star wars fan and just had his fourth birthday yesterday. To help celebrate, I surprised him with a pair of your giant lightsabers…