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TOPIC: Kylo Ren - NeoPixel Crossguard

Kylo Ren - NeoPixel Crossguard 11 months 2 days ago #72742

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Current state at start of thread:




Inspiration for this build came from measurements of the PropShop saber. Turns out most of the off-proportions on the Black Series hilt stem from shortening parts, so major modifications are a thinner/longer handle and longer exhausts.

(Black Series vs Prop Shop)




And here's my current mod to the right of a stock BS hilt (raw aluminum digitally darkened):



Pulled off the handle shroud. Moved the pommel lower on the hilt, and I'll be machining new details to the base pipe. Machined new, longer exhausts from aluminum tubing - now I just need to properly shape them.

This build's slow-going. There's a TFA Graflex that's my top priority, so I'm just squeezing in dremel-time in spare moments. Still hoping to have it ready for MegaCon in late May.
Last Edit: 2 months 1 day ago by Kouri.
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Kylo Ren - BS Overhaul WIP 11 months 2 days ago #72743

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Very cool. Loved the scratch built Kylo you did last year, can't wait to see how awesome this one turns out.

Based on the mods, I assume a full gut?
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Kylo Ren - BS Overhaul WIP 11 months 2 days ago #72747

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Electronics are still up in the air.

If it's just the Knights and me, I'll leave the stock board, bypassing the on-board resistors and hooking in some TIP41 transistors to allow full power to each LED, while using the extra hilt length to fit a removable 18650 and speaker jack in the battery/speaker holder.

If we wind up getting a bigger group and prepping a Last Jedi vs Knights of Ren skit, I'll do a fresh install with Igniter/Zigbee and have one of the Knights lug a portable Hornet-speakerbox.
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Kylo Ren - BS Overhaul WIP 11 months 2 days ago #72749

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Sounds awesome, eagerly following this one.

Slight aside, A Kylo hilt is on my personal list after I get the OT hilts completed. So maybe towards the end of the year. Based on your expertise with the Kylo hilt, I may hit you up to build/paint the empty hilt. Wouldn't be for a while, but I love how your Kylo hilts have turned out.
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Kylo Ren - BS Overhaul WIP 6 months 2 weeks ago #76633

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Finally got around to detailing the body.

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Kylo Ren - BS Overhaul WIP 6 months 1 week ago #76643

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That's a sweet looking build so far. It looks very accurate. :)
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Kylo Ren - BS Overhaul WIP 6 months 1 week ago #76647

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Very nice!
"I am the Senate"
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Kylo Ren - BS Overhaul WIP 6 months 1 week ago #76662

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Am really liking this version. :)
Last Edit: 6 months 1 week ago by Dauntless 7.
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Kylo Ren - BS Overhaul WIP 6 months 4 days ago #76856

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Thanks all!

JB Weld is curing on the hilt components, but I just about wrapped up the electronics. Just completed the new battery sled with 18650 holder and audio jack, so here are the saber guts wired into a portable amplifier:

https://www.instagram.com/p/BWqpwTAgX84/

Beyond that, the soundboard's been rewired to allow full power to all LEDs. Sadly, pumping 4000mA through the board seems to cause some feedback in the audio circuit (not in the above video since the LEDs aren't wired), but I'll just chalk it up to the whine of a cracked kyber crystal.
Last Edit: 6 months 4 days ago by Kouri.
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Kylo Ren - BS Overhaul WIP 6 months 4 days ago #76869

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did you reuse the parts for the outer handle details or did you have to make that from scratch?
RELEASE THE KRAKEN!
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Kylo Ren - BS Overhaul WIP 6 months 4 days ago #76878

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The smaller molded plastic details were reused, but the original metal shroud was scrapped and replaced with thinner/longer aluminum bars.

And for anyone interested in the guts, here's a shot of the hacked board:




And the custom-printed battery sled:



The printed portion of the sled is purposely a bit wider than the original parts on either end to make up for the extra space after removing the internal plastic sleeve that was originally inside the body.
Last Edit: 6 months 4 days ago by Kouri.
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Kylo Ren - BS Overhaul WIP 6 months 3 days ago #76922

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Finally got all the wires joined and gave the hilt a coat of primer:

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Kylo Ren - BS Overhaul WIP 6 months 3 days ago #76927

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Nice! The staggered ignition looks very well timed, about how it is in the film.
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Kylo Ren - BS Overhaul WIP 6 months 2 days ago #77016

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Major update is most of the parts are now primed in flat black.



Also tackled a minor issue. I mis-measured and wound up printing the battery sled a bit too short to make proper contact with the soundboard - some clashes shut the saber off. It's a quick and easy fix though. Drew up a 1mm spacer that plugs into the base of the sled and shims everything into a solid connection.







That last close-up of the sled shows off the shiny silver audio jack that allows sound to feed into my portable amplifier. To the lower right of the jack is one of three channels I cut into this piece to allow sound to vent - the plan is to fill in the original sound holes in the pommel for a bit more accuracy.

Plan for this weekend is to wrap up paint on the hilt and belt accessories. Sewing all next week.
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Kylo Ren - BS Overhaul WIP 5 months 4 weeks ago #77091

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Majority of the paint wrapped up. Just need to finish the wire holders and belt clip before I clear coat and snap photos.

Unstable blades fitted:
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Kylo Ren - BS Overhaul WIP 5 months 3 weeks ago #77189

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This is about as far as I'm getting with the saber before the con, so have a quick comparison between the original Black Series hilt and this heavy-duty conversion:





(first image clickable in case you want to zoom in on the details)

Now I can give the rest of this week to fixing up the costume.
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Kylo Ren - BS Overhaul WIP 5 months 3 weeks ago #77293

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DUDE.....

AWESOME!!!!!!! I can't believe how sweet that looks.

This makes me all the more excited for my Kylo hilt to arrive!!!!!!! Talk about inspiring.
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Kylo Ren - BS Overhaul WIP 4 months 2 weeks ago #79197

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Had this in pieces for a while to investigate the audio whine from the crossguard circuit. Turns out there's no preventing it without going for a custom soundboard, so soldered everything back up and hit the hilt with a gloss coat.



I'm usually opposed to gloss on cosplay pieces (a bad job can make pieces look plastic), but just about everything on Kylo's supposed to shine to prevent his design from being a formless black blob.

Also made some replacement clips and test-fit the new transparent red wire.



I'll try for a proper photoshoot after the hurricane passes,
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Kylo Ren - BS Overhaul WIP 4 months 2 weeks ago #79198

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Kouri wrote:
I'll try for a proper photoshoot after the hurricane passes,

Good idea, stay safe. We can certainly wait for some photos. :)
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Kylo Ren - BS Overhaul WIP 4 months 1 week ago #79544

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Didn't have a chance to sit down and work on anything while prepping for the storm - but kept the printer going until the power went.

Ran a few vertical display stand variants through:



(First (with the saber model) was never produced. Second printed fine. Tried the third to save material, but needed a brace for support - hence the added part in the fourth. Fifth printed fine.)

Currently sitting on one of my shelves:



Need to get to painting on another project, but with any luck I can snap some better photos of everything while the clear's curing.
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