Building Your Own Lightsaber: DIY Guide to Customization and Assembly

Star Wars fan assembling DIY lightsaber using detailed guide.

As the chosen weapon of individuals who wield the force, the Star Wars lightsaber is nothing short of a masterpiece. In the Star Wars films, the crafting of this weapon is a rite of passage for Force-sensitives as the owner (wielder) of each saber will need to carefully pick out its individual parts before delicately and meticulously assembling them together.

This rite of passage is no different for Star Wars fans who have decided to embrace the force by building their very own lightsaber.

Thanks to modern technology and the Internet, building or customising a lightsaber replica has never been easier. Below is a short guide you can follow to build your very own custom lightsaber.

Make Plans

First things first, you need to consider the type of lightsaber you want to build (standard lightsaber, shoto lightsaber, dual-phase, etc.), what it will look like (blade colour and length, hilt style, button placement), and what you plan on using it for (display, dueling or cosplay). Making plans help you not only visualise your concept but also create a list of all the needed parts.

Lightsaber Parts

There are several important saber components and parts that you’ll need to build a good-quality replica lightsaber. Some of these parts may be available at your local hardware store while others will need to be special ordered from manufacturers or online lightsaber stores. The saber parts you need include;

The Blade – Replica lightsabers typically feature polycarbonate blades, and depending on the saber’s intended use, there are three different grades of blade you can go for. A low-grade (very thin-walled), mid-grade, or a heavy-grade (thick-walled) polycarbonate blade. For a standard lightsaber that can be used for both sparring and cosplay, what you need is a thick wall 1-inch (outside diameter) polycarbonate blade (tube) that is about 30-36 inches long. There are more unique options, such as a Darth Maul lightsaber which can be more difficult to calculate measurements.

The Emitter – This is the saber’s blade holder. It supports and stabilizes the saber’s blade during use. They can also add to the aesthetic appeal of a lightsaber. Most online lightsaber stores carry an array of very attractive and functional models of lightsaber emitters that you can easily purchase.

The Hilt – This is one of the most important parts of a lightsaber. It is the part that a wielder grips. It also houses the saber’s electronics (power source, soundboard, speaker, and emitter). Online lightsaber stores also carry several hilt styles and designs, including replicas of some of our favourite character’s hilts. For a standard lightsaber build, a 12-inch long metal hilt with a 1.5-inch chrome sink tube is ideal. You will also need a sink tube adapter to attach the blade holder (emitter) to the sink tube. The hilt should also come with a switch or button and an end cap (pommel).

The Pommel – This bottom-most part of a lightsaber’s hilt performs the function of providing the saber with counterbalance. It is what ensures that the saber doesn’t slide out of the wielder’s hand during use. Pommels also come in different designs, and they can add to the visual appeal of your saber.

The Soundboard – Another very important saber component is the soundboard. You can choose to either buy this from an online lightsaber store or pull one out of an old lightsaber toy.

The Electronic Guts – This includes a high-power LED (with a lumen output above 60). You will need to decide between buying an LED that emits a specific colour or a white LED in combination with colour filters. You will also need to get an optical lens that’ll focus the light. Other electronics you need include; a battery holder, a vibration motor, speakers, and a crystal chamber.

You can personalise your lightsaber more by adding other unique parts like coloured trims, etching, leather, jewels, and a grooved section to the hilt.

Assembling the Parts

Once you’ve got all the parts needed for your replica lightsaber, the next step is assembly. Assembling the parts of a replica lightsaber can be tricky, but thanks to the Internet, there are several DIY instructional videos to help you with this. Alternatively, you can visit a lightsaber customisation workshop to have the experts guide you on how to put your saber parts together.

Final Thoughts About DIY Lightsaber Building

As a Star Wars fan, building your very own lightsaber is one of the first steps you’ll take toward embracing the force. Lightsaber customization also affords you the opportunity to add your own personal and creative touch to the appearance and function of your lightsaber.

Zohaib Ali

Zohaib Ali is a web designer and very passionate and dedicated to his work, with 20 years of experience as a professional web developer. Zohaib enjoys every step of the design process, from discussion and collaboration. Look for more of his work on AITrueReview.

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