Oh my God I haven't played that game in YEARS. I used to play it soo damn much on MSN Gaming Zone waaaaay back in the day! Such an awesome game! I should reinstall that and play that or Jedi Outcast again!
I haven't seen anyone here have one built, but a google search for images shows people have managed to build some very faithful replicas of Kyle Katarn's lightsaber. Your best bet might be to start there to track something down.