Converting a Graflex to a Darth Vader ROTJ style saber

 
Introduction
Parts
Template
Drilling
Ear Bending
Test Fit
Painting
Bottom Shell
Install Parts
EL Elect.
The Joining
Finishing Up
Finished Pics

 

Drilling

I drilled out the holes to 7/16" per the template and then setup to chamfer each hole so that the angle of the tapered hex bolt head would sit just in the hole with out falling all the way into the body and sit just about flush with the outside of the tube. This part can be very tricky if you have never done it before so be very cautious and take your time.

 

This is the style of industrial chamfer bit that I used.

 

Graflex Conversion, Nuts and Bolts

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