Quick Lightsaber
To create a lightsaber, first decide the color you want your sword to be. The colors typically seen in the Star Wars films are green, blue and red. A lightsaber, however, can be any color.
Begin crafting the sword by choosing different length cardboard tubes. You will need a long tube for the blade, the tube from a roll of wrapping paper would be ideal, as well as two smaller tubes for the handle. The handle can be crafted from two toilet paper tubes.
Cut the two small tubes so that they connect and cross each other through the middle, forming a T shape. This will be the handle. Secure the two tubes together. The handle should be a metallic color, such as black or silver. Research the markings on the handle through the films or online. Paint or draw the small details with marker or black paint.
Color or paint the larger tube your desired color. You can use a glow in the dark craft paint so the lightsaber will have an eerie glow in dim lighting as the real ones in the film do. Attach the colored blade tube into the handle and secure.
Cut small slits in the top of the blade tube and fold the flaps into each other to close the opening on the top. Repeat this with the bottom and sides of the handle. Secure the flaps with tape or glue.
Durable Lightsaber
There are many websites that offer detailed instructions for building more realistic lightsabers, such as BigYellowBox.com. On their site, they include a list for parts as well as provide detailed instructions for building it. According to BFX in their YouTube video, they made a variation of a lightsaber from BigYellowBox designs for $35.
Here is a list of parts used for building a more durable and lifelike lightsaber, according to BigYellowBox.com.
--3/8-inch bolt 3 inches long with a 7/16-inch head
--1 1/4-inch EMT box connector set
--1 1/4-inch compression connector
--6 zinc flat washers, 5/8 inch
--3/8-by-2-inch steel pipe nipple
--ballcock shank washer (toilet part)
--1 3/8-inch wood curtain rod
--1 Garrity Tuff Lite flashlight (2-cell)
--1 Popular Mechanics swivel aerator (pm30862)
--2 10-packs of Popular Mechanics hose washers (pm93114)
[only 12 are need for this project]
--o-rings, 2 small and 2 large
--1 eye-screw
--black paint
--black duct tape
--black construction paper
--small red lamp (available at Radio Shack, cat.Đ-345)
--small black (or painted black) wood screw
--several very small o-rings (to act as spacers between the bolt and the pipe nipple)
--6 small self-adhesive black rubber bumpers