For the blade I recommend translucid PETG in spiral vase mode with 0.85mm extrusion width.
- Print all the parts, including the blade and hilt from 3dprintingworld's Lightsaber
- Disassemble the flashlight, you will need every part that is inside, including the glass and reflector(most important piece).
- Unsolder the battery connector from the charging board and solder the battery cables directly (to save space)
- Unsolder the on/off switch from the board (the wires from the microswitch will be directly soldered there later).
- Replace the wires that go from the charging board to the LED board with longer ones.
- Prepare the microswith soldering cables on the C and NC pins (not the middle pin). Use thin wires for this one, I'm using 30AWG wrapping wire.
Bend the microswitch legs like the picture above (mind the side). The middle leg can be cut out or bent.
Finished Reflector Holder LED Assembly (without the reflector)
Solder the wires like in the picture above, then insert the board with the shorter side first and then then rotate it passing the cables through the holes.
- Insert the microswitch on it's slot passing it's cables to the other side (double check the correct switch position before pushing it in). The switch is somewhat sensible from being pressed from it's lever, so use a screwdriver to push the switch from under the lever. The switch should snap in place.
- Push in the flashlight glass on the lightsaber cap until it's locked in place.
- Insert the reflector, which will also help hold the glass in place.
- Insert the assembled reflector holder (with LED) and rotate it to lock (use some silicon grease if it's difficult to rotate). Check if the led is correctly centered inside the reflector (it should be).
- Solder every thing to the charging board, insert it with the battery and close with the charging cap.
- Insert the blade into the hilt, close with the cap and test it. The light should be off when the blade is inside the hilt.