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I've carved an Ebony handled, 2 handed, Light Sabre prop for Halloween. I have machined an aluminum shaft to house an clear acrylic rod with a pocket milled in it to embed a LED flashlight 'Beam'. This can be seen in the Prototype photo. I then bored the Ebony to fit around the aluminum hilt. There is a thumb trigger for the light and is held in place with threaded cap screws. I still have some ribbon detail to complete the project. Hopefully it'll be done in time.

UPDATE: The exposed portion of the Acrylic "beam" is 32" long. I was just at the 1$Dollar Store and found a 9LED light for 9x's the brightness. That would have been perfect if I had this when I machined the aluminum. Of course I don't have access to the turning machine for another attempt. Oh well, Cest La Vie.

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Just needs a leather strap to keep it from flying away, when you get busy fighting off the dark side. (unless you are the dark side)
 

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The Force is strong with you: Young Jedi
Gret work!
 

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Wow! This is a phenomenal idea! Better add the tag "star wars" to this project! I love how the carving makes the handle appear to be wrapped in leather!
 

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May the Force be with you!! Say Hi to R2D2 & OB1-kenobee for me.:) Nice work and idea BTW.
 

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How long is the Rod? Wish there was a way to make a determinite lenght beam without the acrylic rod!! That would be KOOL!!
 

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Great looking handle, nice!
 

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May the force be with you!
Mads
 

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UPDATE:
The exposed portion of the Acrylic "beam" is 32" long.

I was just at the 1$Dollar Store and found a 9LED light for 9x's the brightness. That would have been perfect if I had this when I machined the aluminum. Of course I don't have access to the turning machine for another attempt.

Oh well, Cest la Vie!
 

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neat
 

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For the sake of the project your probably better off without the 9x Led Flashlight. I bought set of three and went through 1 a month. The Led's are good but they lose connection with the power so you have to smack it to turn it on and off. After a while even that wont work. Cheep Construction! Which is why it would be bad for such a wonderful piece of work you have created. Also an Idea for your blade is to find a way to frost the outside of the acrylic which will split the light out the entire length instead of just the ends. But you may want to experiment with this before you apply it to your finished project.
 
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