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7 Watt Laser LIGHTSABER Build!! NUBM44

HydroSean

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Hey guys, I recently purchased the Guardian lightsaber empty hilt from Ultrasabers to make a high powered real laser lightsaber with. You can see the unboxing and dimension pics of that host here.

http://laserpointerforums.com/f72/ultrasabers-guardian-unboxing-dimensions-warning-pic-heavy-98232.html

I purchased this NUBM44 diode in the module and driver from DTR, this guy is so helpful and nice I am greatful and will continue to purchase many diodes from him. Also many thanks to LPF here you guys are a lot of help too! MUCH THANKS!

Before I begin let me just say this build was A LOT more involved than I had planned it to be, but after 4 years of being challenged in chemistry I knew this was a task that I could surmount and subjugate.

I had to get the inside of the host turned on a lathe because there were two IDs to the host and the distance from the battery opening (which is the larger ID) to the smaller ID was not enough room to fit the batteries inside. So I had to go to an engineer who has a metal lathe to get the larger ID turned to at least 5.875 (ended up being about 5.9) inches. Other than that I was able to do everything on my own :D

Okay here we go :D If pictures bore you just scroll down to the video! :D

I first had to make the battery contact boards custom because no one makes 1.280 inch boards :p


I noticed that the inside of the screw-cap was anodized so I got out some greased lightning and etched away some of the inside as well as the part that touches the main host. Then I sanded away the remainder debris.


Now that it was all ready for the negative contact board, I weaved a wire through the spring and the board around the edges so I didn't have to mess with soldering to aluminum.


Here's the flip-side of the screw-cap.


I thought about how I was going to solder all the wires inside to the switch so I needed an access hole. So I drilled a 5/8 inch hole just above the switch hole. Don't worry, the lightsaber sleeve covers this part, I will also use this to ground the driver shown later below. My drill press even has a laser on it!!



Since the 25mm copper module would get pretty hot I figured I'd buy a heatsink just for the driver. Here is what that looks like.


I mixed up some Arctic Alumina thermal epoxy and applied it to the driver and heatsink.


The driver with the heatsink fits just barely inside the top end PHEW!


I pulled the wires through the switch hole and soldered them to the switch.


I threaded the ground to the SXD out the hole I drilled and secured it with tape. I later just pinched it to the sleeve that slides over the host because the tape kept coming off.


After sliding over the sleeve, press-fitting the button, and securing the diode module with the set screw I was in business! I have to admit I was a little skeptical this would not work but it did FIRST TRY haha. Anyway without further ado here it is along with an obligatory video I made burning things.






https://youtu.be/W_lIc6VQPIM
 
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diachi

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Nice build, that's a massive host! I like it! :D
 

Sta

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Fantastic build! I'll be making one of my own as soon as the host (SaberForge Reborn) gets here.
Somebody +rep this man, he deserves it! I must spread some around first. :)
 

ElectricPlasma

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LOL why did the muffin cup randomly shoot up in the air?

Nice build though, the host looks massive.
 

Pman

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Yeah nice job. Killed me everytime you placed that beautiful Saber on the concrete;)
Sometimes what I do to make sure the contact board is going to touch is use a very thin piece of copper and put it on the side like you did with the wire and then press the board in place and then cut it short enough where it is sticking out so when I bend it over it will contact the board edge and I solder it to the outside edge of the contact board. I just did that yesterday on a unit I repaired for someone but it's already packaged up to be mailed or I would show what I mean.
 
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HydroSean

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LOL why did the muffin cup randomly shoot up in the air?

Nice build though, the host looks massive.
Just build a free body diagram! There is more force pushing up the ashes than gravity pushing down, but where does the upward force come from you ask? When the top of the coffee filter is lit it heats up the air underneath the filter. This makes a hotter environment below the paper than above the paper. Since the ashes are extremely light the flow of hot to cold has enough energy to overcome gravity!


Yeah nice job. Killed me everytime you placed that beautiful Saber on the concrete;)
Sometimes what I do to make sure the contact board is going to touch is use a very thin piece of copper and put it on the side like you did with the wire and then press the board in place and then cut it short enough where it is sticking out so when I bend it over it will contact the board edge and I solder it to the outside edge of the contact board. I just did that yesterday on a unit I repaired for someone but it's already packaged up to be mailed or I would show what I mean.
Haha I set it down with care each time but hey I figure Obi-Wan Kenobi has lost his lightsaber twice and dropped it more and even from greater heights. It may give it more of a realistic look :p
Good idea for the contact board I will keep that in mind for my next build, however I think with this host I am getting from survival lasers the contact board comes with it. :D
 

Pman

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I checked out the unboxing but didn't notice the price anywhere on that host....
 

HydroSean

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I checked out the unboxing but didn't notice the price anywhere on that host....
I put the link to where I purchased it from Ultrasabers, here's the link from the thread.

The Guardian | DIY Empty Saber Hilt| Ultrasabers.com

I got the guarded latching switch and the Allen key as well which bumped it up to about $140 but the raw empty hilt without the switch or Allen key or anything is $129
 
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MassiE46M3

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Absolutely beautiful buddy. Gorgeous looking saber. I'm extremely new to the laser world but this is exactly what I want to be doing,, I want to do builds like this. Again astonishing work!
 

Pman

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I'm assuming you can't add the blade at this point because the sink is in the way. Would like to see it light up even just for a quick flash:)
So what are you thinking for your next project? Going to stick with the Saber theme?
 

DTR

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Awesome build. Glad to see it turned out so nice.:beer:
 

BowtieGuy

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Great build, love that host! Good job on the detailed unboxing and the step by step photos! :beer:
I've been interested in using a lightsaber for a host for a while; may have to pull the trigger after seeing this beauty.
:gj: +rep
 

HydroSean

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Great build, love that host! Good job on the detailed unboxing and the step by step photos! :beer:
I've been interested in using a lightsaber for a host for a while; may have to pull the trigger after seeing this beauty.
:gj: +rep
I forgot to include something in my build BTW sorry it slipped my mind, I will add it to the thread after this post. I had to get the inside diameter of the battery opening turned (lathed out). There were two inside diamters, one was 1.320 inches and the other was 1.20 inches. The distance from the battery end to where the ID got smaller was only 4.5 inches and I needed at least 5.875 inches to fit the battery assembly inside. So I went to this engineer to get the larger ID turned to go at least 5.875 inches into the host. Thanks for the rep! :D

I'm assuming you can't add the blade at this point because the sink is in the way. Would like to see it light up even just for a quick flash:)
So what are you thinking for your next project? Going to stick with the Saber theme?
I can add the blade, I would just have to install an additional set screw lower to hold the laser module in place, it has room to move downward, but I will save that for a future project on a different saber now that I have some experience.

I have already ordered my next laser from DTR and it is the M462 (462nm) laser and I am going to put it into the S4 extended battery case host from Survival lasers. I am going to post the build of it next week when the host arrives. The laser in the module has arrived from DTR (that guy is awesomely quick at shipping btw) and have tested it and it works amazingly!

Absolutely beautiful buddy. Gorgeous looking saber. I'm extremely new to the laser world but this is exactly what I want to be doing,, I want to do builds like this. Again astonishing work!
Thanks mate! Much appreciated :D
 
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