"Youngling Slayer" Lightsaber Chassis

This is an internal chassis for the “Youngling Slayer” Anakin Skywalker lightsaber replica by Shadowfoil Props / Laredo Sabers. It was designed primarily to accommodate a larger battery and support more widely available, non-proprietary tactile buttons. Its main features include:

• Support for larger, 21700 battery
• Detailed battery cover
• Optional, detailed crystal chamber with support for single-pixel LED lighting
• OLED screen
• Uses standard tactile switches for the primary & AUX buttons (e.g. this)
• Thoughtful aesthetic design

Assembly Guide

Comments

The chassis has two main components: an internal “upper” section and a removable lower section. They are both designed to be inserted in a single orientation, with internal grooves to guide appropriate insertion into the saber.

• Upper section (not shown): Includes the neopixel connector and the two momentary switches (main & AUX). 
  • NPXL connector: Uses a standard, widely available NPXL connector with 17.5 mm OD
  • Main button switch: Uses a standard momentary tactile switch (e.g. available here). Fits into the upper section.
  • AUX button switch: Uses the same tactile switch as above, but this switch fits inside the saber, not the chassis. For wiring, I recommend first wiring up the upper section with the two AUX button wires sticking out the side of the appropriate hole in the upper chassis. Complete all wiring and assembly of the upper section, saving the AUX button wiring for last. Then, thread these AUX button wires through the saber and out the AUX hole in the saber. Finally, solder the wires to the tactile switch and insert into the AUX button slot. The upper section chassis can then be inserted into the saber, where it will be left permanently. This links the upper chassis section to saber, making this part effectively non-removable. 
  • 10-pole chassis connector: This sits at the opposite end of the NXPL connector, linking the upper section to the removable lower section. This 20 mm OD part is available at severable saber shops (e.g. here)
• Lower section (shown in photos):
  • 10-pole chassis connector: The top of the lower section contains the male portion of the aforementioned 10-pole chassis connector.
  • Crystal chamber: The chamber contains a 6 mm ID “floating” crystal holder which supports crystals up to a height of ~ 17 mm. It includes a hidden, recessed section for holding an 8 mm single pixel PCB, for crystal chamber lighting. I included a 3D-printable crystal design; the included photos show this crystal printed in transparent PETG.  I have also included a variant lower section without the crystal chamber, which provides more working room inside the chassis for wiring, if a CC is not desired.
  • OLED screen: This is designed for OLED screens provided by The Custom Saber Shop (0.459" x 1.237"), although other OLED screens by different retailers are likely to fit.
  • Decorative wires: There is a section for two decorative wires on the side of the chassis, which are optional. They will fit up to 1.4 mm diameter wires (~22-24 gauge or smaller). I added these to pay homage to the exposed wires in Vader's saber in ESB.
  • Removable 21700 battery
  • 28 mm speaker

Parts List

• NPXL Connector (17.5 mm OD)
• 10-pole Chassis Connectors (20 mm OD)
• 2 x Low-profile Tactile Switch (6 x 6 x 3.1mm)
• Proffieboard
• OLED screen (0.459" x 1.237")
• 8 mm single-pixel circular PCB, for crystal chamber (optional)
• Removable 21700 Battery
• Battery contacts set (e.g. here)
• High-amp kill switch
• 28 mm speaker
• Wires

License & Use

You are free to use and modify this for personal use. You may not use, sell, or modify this design for commercial purposes.