I used eBay for the blade stock but ended up having to stick with the homemade resin made one which is the only part of the build I'm not happy with. For the next one I will probably contact one of the U.K. based Saber makers to get blade tips, but for this one I wanted to build from parts that weren't 'Lightsaber parts'.
I started with some aluminium tube with an ID of 1" from eBay
I then had a massive stroke of luck in finding that the mother in law had a 'brother scan n cut' which allowed me make my design on the computer and then cut it onto an a4 sheet of vinyl sticker.
I then stuck this onto the aluminium and used the saltwater etching method described here
http://www.instructables.com/id/How-To-Electro-Etch-a-Solid-Metal-Plaque/
I used a car battery charger for the power source and a metal scouring pad as the sacrificial metal (be careful as it was drawing over 10amps whilst etching). It took about 20 mins to etch, moving the Saber every 5 mins or so to get an even etch (don't forget to turn the power off!)
For the blade I used 1" acrylic tube from eBay(basically everything was eBay) and cellophane wrap with a custom made resin tip (again thanks to the mother in law) with a small metal disc as a reflector.
The light is a small Cree led torch
Here that I ripped the button out of and wired to an external latching switch
here. This was all mounted inside another 1" poly tube that I had from a previous Saber
I Then attached the electronics (glued into the poly tube) and the blade inside the tube using some bolts through holes that I drilled and tapped into the aluminium tube.
I think that pretty much covers it but if anyone would like more info then I'd be more than happy to post more.
I have really enjoyed discovering a new hobby and will be trying a more 'traditional' single Cree LED and cheapo Hasbro board build next!