How to Build a Blade for My Lightsaber

Drill a hole in the side of the hilt large enough to install the push-button switch. It should be the kind that clicks on, then clicks off.

Attach the positive and negative wires to the button by twisting it onto the contacts (the contacts should be labeled with a + and -). Thread them in through the hole in the side of the hilt and out the top.

Attach the toggle switch to the hilt with epoxy. Follow the epoxy manufacturer's instructions and allow it to dry before continuing.

Open the flashlight and remove its built-in switch.

Attach the wires from the push-button switch to the connection points for the flashlight's switch. The method for this will vary depending on your flashlight, but you should be able to solder the wires to the connection points or maybe even twist them onto the existing wires. Doing this basically has the same effect as an extension cord: you've replaced the flashlight's original switch with an external one.

Test the flashlight's new button to make sure it works.

Push the excess wire and the flashlight into the hilt.

Secure the flashlight in place by squeezing a bead of epoxy around the top of the flashlight and onto the hilt.

Insert the plexiglass rod into the handle on top of the flashlight and mark how deep it goes.

Spread epoxy on the part of the rod below your mark and re-insert it into the hilt. Allow the epoxy to fully dry before trying out the lightsaber.