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How to Make an Expanding Lightsaber

In 1977, George Lucas made the biggest science fiction film series ever created. As of February 2011 the Star Wars movies have made over 4 billion dollars, influencing almost all sectors of advertising. The Star Wars movies set off a chain reaction, producing action figures, puppets and toy weapons. One of the most popular weapons was the light saber. An expanding light saber can collapse to as small as 2 feet and telescope out to nearly four. By creating your own expanding light saber, you can add your own personal twist.

Things You'll Need

  • 72-gauge plastic sheeting, 12-by-21 inches
  • Shears
  • Razor knife
  • Rubber Cement
  • One 2-inch diameter rubber gasket, 1/16-inch thick
  • One 1-inch diameter rubber gasket, 1/16-inch thick
  • Tube flashlight with 3-inch diameter lens cap
  • Flashlight batteries
  • Translucent spray paint
  • Opaque spray paint
  • Tape measure
  • Marker
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Instructions

    • 1
      Use a flashlight with a cap diameter of 3 inches.

      Unscrew the lens cap of a tube flashlight. The cap should have a diameter of 3 inches.

    • 2
      Use a pair of shears to cut the plastic sheet.

      Cut a piece of 72-gauge plastic sheeting 1 foot wide and 10 inches long. Use a pair of shears or a razor knife to cut the plastic.

    • 3

      Wrap one end of the plastic tightly around the flashlight cap and taper the other end down to a 2-inch diameter circle; the resulting structure should look like a plastic cone.

    • 4

      Mark the seam of the cone where the plastic overlaps. Unroll the cone, and cut off any excess plastic leaving 1/2 inch to overlap the edge. Coat the edges of the plastic with rubber cement. Wait 15 to 30 minutes for the adhesive to become tacky, and re-form the cone shape while pressing the two edges together. Hold the seam together until it stays without assistance; this will be the base cone.

    • 5

      Cut another piece of sheeting, 1 foot long by 7 inches wide, and fashion another tapered cone going from a diameter of 2 inches to a diameter of 1 inch. Mark the seam of the cone, cut off any excess plastic, leave 1/2 inch of overlap, and glue it with rubber cement in the same manner as the first cone; this will be the middle cone.

    • 6

      Apply rubber cement to the inside of a 2-inch diameter, 1/16-inch thick rubber gasket. Let it tack up for 15 to 30 minutes and slide it around the 2-inch end of the cone.

    • 7

      Cut a third piece of plastic 1 foot long by 4 inches wide. Shape the plastic into a cone going from a 1-inch diameter circle to a 1/2-inch diameter circle. Mark the seam, cut off any excess plastic, leaving 1/2-inch for overlap, and glue the cone back together with rubber cement.

    • 8

      Cut four 1-inch deep slits evenly apart into the 1/2-inch diameter end of the cone so that you have four small tabs.

    • 9

      Coat the plastic tabs with rubber cement. Let the adhesive tack up and fold the tabs on top of each other the same way you might fold a box top. The resulting structure should look like a cone with a closed bottom; this will be the head cone.

    • 10

      Coat the inside of a 1-inch diameter, 1/16-inch thick rubber gasket. Give the adhesive 15 to 30 minutes to get tacky and slip it onto the 1 inch diameter end of the cone.

    • 11
      Slide the cones into one and other so they resemble a telescope.

      Slide the head cone into the middle cone, small end first, until it pops out the 1-inch diameter side, the gasket will keep it from coming out completely. Slide the middle cone into the base cone in the same way. You should now have three cones that slide out of each other resembling a telescope. The gaskets will hold each cone in place. Push the head cone down to collapse the cones into one another.

    • 12

      Coat the 3-inch diameter end of the base cone with rubber cement. Apply rubber cement around the cap of the flashlight, and wait 15 to 30 minutes for the rubber cement to tack up.

    • 13

      Lodge the flashlight cap into the 3-inch diameter end of the base cone, and hold the two pieces together until they remain connected without your aide.

    • 14

      Put the appropriate batteries into the flashlight, and screw the cap back on.The light saber will light up with the flashlight.

    • 15

      Use translucent spray paint for the cones and opaque for the handle. Decorate the light saber to your preference.


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