Take the 1-1/2" x 12" extension tube. The cap and washer will not be
You need to use the rotary tool to cut off the threaded section of the
tube. Unlike before when you cut the emitter section, you do not want to
leave a small flared lip on the tube. You do, however, want to cut only
the small flared section off so that the large flared section of the tube
ends with no further flaring at all.
Now cut off the other end of the tube so that the overall length (after
cutting off the threads) is 6". Even with the larger cut-off wheel it can
be a pain to cut off this section of tube due to not being able to get
the rotary tool close enough to the tube and still keep the right angle.
I ended up cutting off the excess tube in sections until I got close enough
to the real cut and then took my time with that one. On
hindsight what I recommend is cutting it off at about 7" with a hack saw
to get you easy access with the rotary tool for that last inch.
Make yourself a paper pattern for the grip cut-out. Something
like this is what I used, but this a good place to personalize your saber
with a cutom pattern.
Tape the the pattern down with the least tapered side at the base of the
flaring section of the tube. Remeber that extra tape around the cut lines
will help keep you from scratching your tube with a stray move. With the
pattern in place cut out the grip with a cut-off wheel.
Clean up the cuts and fill out those corners with the sanding drum.
#2 Parts List
Emitter Tube Base
Tube Grip Tube
Pommel Tube Clip
Knob Emitter Assembly
Grip Assembly Pommel