Summary
Fully modular version of Rey's new yellow lightsaber that allows for Neopixel sound electronics that can be activated with a film accurate cog switch
Post-Printing
Electronic Materials
-Crystal Focus Sound Module X MK3
https://www.thecustomsabershop.com/Crystal-Focus-Sound-Module-X-MK3-P1530.aspx
-Panasonic Li-Ion 18650 3.7V 3400mAh PCB Protected Rechargeable Battery
https://www.thecustomsabershop.com/Panasonic-Li-Ion-18650-37V-3400mAh-PCB-Protected-Rechargeable-Battery-P853.aspx
-MWS Recharge Port
https://www.thecustomsabershop.com/MWS-Recharge-Port-P877.aspx
-Kill plug style 5 - Blue
https://www.thecustomsabershop.com/Kill-plug-style-5-Blue-P1246.aspx
-Saber Essentials 28mm Stealth V2 Speaker
https://www.thecustomsabershop.com/Saber-Essentials-28mm-Stealth-V2-Speaker-P1364.aspx
-Pre-Soldered Pixel PCB connector and 11 pin set
https://www.thecustomsabershop.com/Pre-Soldered-Pixel-PCB-connector-and-11-pin-set-P1416.aspx
-16mm Anti Vandal Momentary Stainless Switch
https://www.thecustomsabershop.com/16mm-Anti-Vandal-Momentary-Stainless-Switch-P471.aspx
-Magnetic Contact, Recessed Mount
https://www.zoro.com/zoro-select-magnetic-contact-recessed-mount-2exu8/i/G1648053/?utm_source=google&utm_medium=surfaces&utm_campaign=shopping%20feed&utm_content=free%20google%20shopping%20clicks&gclid=CjwKCAjw7IeUBhBbEiwADhiEMdTRwFh7PNywX990grWNqB9ELhZEM78IGFGvpHSsd1xA2t7ohhh01BoCxr8QAvD_BwE
-5 mm Diameter Magnets
https://www.amazon.com/WOBATOY-Personalized-Multi-Use-Whiteboard-Refrigerators/dp/B075PMRBWJ/ref=sr_1_7?keywords=5mm+magnets&qid=1652763853&sr=8-7
-1 inch Diameter Neopixel Blade
https://www.etsy.com/listing/1081971275/kr-pixelstrip-v2-neopixel-blade-1?ga_order=most_relevant&ga_search_type=all&ga_view_type=gallery&ga_search_query=neopixel+blade&ref=sr_gallery-1-10&frs=1&bes=1&sts=1&organic_search_click=1
JST Connectors
https://www.thecustomsabershop.com/JST-Female-connector-24AWG-RedBlack-P964.aspx
https://www.thecustomsabershop.com/JST-Male-connector-24AWG-RedBlack-P963.aspx
-Tapered Heat-Set Inserts for Plastic
https://www.mcmaster.com/97163A160/
-M3x12mm Knurled Head Thumb Screw
https://www.amazon.com/dp/B01MQIHMFQ?psc=1&ref=ppx_yo2ov_dt_b_product_details
Assembly
Detailed wiring diagrams are found here:
https://www.plecterlabs.com/Media/Doc/Crystal%20Focus%20v10%20rev1.09-GB.pdf
Solder the board power to the recharge connector. Free wire should be able to tuck into the space of the chassis. Note that a positive lead from this connection will need to be reserved to power the neopixel pcb (Manual Page 25)
Solder the board speaker pins to the speaker leads, Free wire will need to easily tuck into the space of the chassis. Because of the cutout in the speaker mount in the chassis, the board, speaker and recharge port should still be easily removable (page 26)
The board can now be tested. Insert the stock SD card into the board and then connect the battery male jst connector into the recharge port female. If everything is working, then the speaker should make a boot up noise.
Solder wires to the activation switch and auxiliary switch leads and allow lots of slack. Colors for all 3 wires should be different (page 26)
Solder wires for the ground and data leads needed for a Neopixel connection. (page 127)
The chassis parts can then be put in place. The recharge port can be locked into the hole near the speaker mount using the included threaded nut. The speaker should snugly fit into the round speaker mount. The battery can snugly fit into the hole at the opposite side of the chassis, leads down. The JST connectors can then be connected to the recharge port and excess wire should be hidden in the battery channel.
Solder male JST connectors to the pre-soldered neopixel pcb, one for the positive lead, one for the negative, and one for data. JST connectors are optional, I used them to make parts easily removable.
Insert chassis into the hilt and feed the neopixel wires through the top and the switch wires through the front. The magnetic switch can be inserted into the hilt and those wires should also go through the front.
Solder JST connectors to the momentary switch and the loose board wires. Make the connections according to the wiring diagrams.
With an appropriate level of slack, the JST connections should be able to be tucked into the hilt. The pin mount part should snugly hold the pin pcb. With the pins inserted, the pin mount can be inserted into the top of the hilt.
The screwing of the top emitter will ensure that the mount will not fall out of the hilt. The tsuba part can then be screwed onto the upper emitter.
Without the kill key inserted, the lower emitter can be freely screwed on to the hilt. With the kill key, the lower emitter will need to be inserted with the inner groove aligned with the kill key to allow for clearance. The same is true when the part is removed. The pommel can then be screwed on.
Change the switch parameter of the board SD card to 3, the locking switch setting (page 40)
Super glue magnets into the small hole of the switch1 part. Then glue the two switch parts together around the collar of the hilt. When on, the board should activate when the cog switch is flicked to the right.
- Use a solder to press a m3 heated insert into the tsuba part. A blade should be able to be inserted and locked in place with a m3 thumb screw.
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