Initiation au bricolage par Serge-Henri
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compteur météo
A sabre of Jedi


Material :
  • 1 silver plated aluminium : 10 x 680 mm.
  • 1 aluminium plate: 250 x 50 x 1 mm.
  • 1 nylon round : 21 x 120 mm.
  • 1 plastic hexagonal head screw : 8 x 30 mm.
  • 1 plastic stopper (diameter 10) for leg of chair.

    Advice :
  • A 6 mm hole will be drilled in the nylon round, well centered : it's better to do it with a hand drill.
  • Then a 10 mm hole need to be drilled only at one end, 80 mm deep.
  • Go a head gently and at low speed even if it means to take several intermediate size drills to get a 10 mm hole. (because when the drill plunges, it is sometimes too late !)
  • As for the other end the rule is : diameter of the screw x 0,8 = drilling diameter a 6,5 mm hole will be drilled.
  • A 10 mm hole will be drilled at one end of the aluminium plate which will be adjusted with the small round file to make slide the tube.
  • The center of this hole is a 25 mm radius half-circle.
  • Round the angles with the shear to give it the shape of a corsair's sabre.
  • A 8 mm hole will be drilled at the other end which while also be rounded.
  • To form the aluminium plate, find a round such as an ashtray, bottle..., which has got a 100 to 120 diameter.
  • Place the plate on it and push on each end until you get the shape you wanted.
  • Do not close too much this trigger guard because it has to remain a bit elastic to be maintained on the tube and the screw, which it will prevent from unscrewing.
  • Force the tube's way in the nylon round : don't forget to protect each element with plywood offcuts and to locate the length which has to be forced in.
  • Then, you can slip the trigger guard on the tube and maintain it well closed it to be able to screw thouroughtly the plastic hexagonal head screw.
  • Force down the stopper.

    Options :
  • You can engrave a first name on the trigger guard with a small drill machine and a 2 mm drill : be careful, do it before forming it.
  • The trigger guard can be made out of plexiglass (minimum thickness : 3 mm). In in this case the engraving will be done inside, the wrong way.
  • Be careful because drilling plexiglass is a very delicate thing to do.
  • Prepare your fixed gauge, put gloves on and heat the plexiglass with a hot-air paint stripper without burning it for about 30 to 60 secondes. (always keep your eye on it)
  • Put the plexiglass on the gauge and form the trigger guard in one go.
  • Take the plexiglass off the gauge by preventing it from opening and pass it under cold water.
  • This way, it will keep it's final form with little elasticity and do not try to heat a second time to draw it a side, it breaks like glass !