here it is my lightsaber is a public file i ask you do not sell it please and thank you you are more than welcome to use it for yourself... now thats out of the way. parts: 1" pex tube from menards (clearishwhite) mine was a 5 foot straight stick (cut to 40") 6$

flashlight menards 20$ or eBay 8$

flash gel eBay different options 8$ for pack of 20 colors

and of course 3d print the 2 files i printed in one piece but i have a big printer you may have to break it down. the hilt prints upside down because there is a ledge inside. this way you don't need support. http://www.thingiverse.com/thing:2024985

the pex tube will have black lettering on it just take paper towel and rub it off it should rub off with a little effort

use small zip ties and a little superglue to keep the flashlight in it extended position. (smallest focus point)

once the parts are printed there is some post processing to keep it strong tolerances are tight. clean up the plug and get it to fit inside of the hilt, then clean up the inside of the plug and get the flashlight botton end to fit through it.

next is the hard part you have to get the flashlight to tightly fit into the hilt basically get the inside smooth i used sandpaper on a dowel rod. the light will not fit from sanding. i had to lightly grind the flashlight to get that perfect fit. (reason for this is so its as tight as possible so it doesn't move around)

next sand the inside of the hilt where the blade goes until it fits

put the flashlight in the bottom and put the plug on the flashlight will be tight in place. now push the blade down to the flashlight so they touch. then proceed to drilling holes in next part

i drilled holes to fit 5mm screws. one for the light(drilled through hilt and plug at same time without flashlight in) and 2 for the blade through the hilt and the blade.

install your 2 screws for the blade

now take the light out and cover the end with a flash gel of choice and reinsert into hilt. put on the plug and put in your set screw i used 10mm for this part.

and there ya go a cheap lightsaber that looks awesome

i want to see them when your done building them

and remember may the force be with you :)