Hi, just a quick update. We got RMA'd parts back today.
The pommel is a brand new one, but still has exactly the same issue as the original one. The shroud's retention screw hole is still in the wrong place so it attaches only at a very very weak part of the inner pommel. So, we swapped in a longer screw again and threaded it hard into the deep part of a groove for increased stability. Without doing this, it would fall apart while dueling (like the last one did). This picture illustrates the misplacement of the shroud hole:
SF shipped a brand new ASP electronics unit instead of replacing just the damaged speaker. The new unit has an
upgraded SaberCore board which doesn't get hot in standby mode, so that's a pretty nice bonus. However, the speaker is still clipping during loud sounds. It's not clipping as badly though; sounds like the speaker is physically intact but overdriven.
Update: With the parts actually installed in the hilt, the sound is totally fine. Not sure exactly why it was clipping in open-air use, but the hilt provides the stability or resonance or lowpass or whatever it needed to sound better. And it seems louder than any of the other sabers I've heard, enough that it tickles my hand through the solid handle of the hilt.
The new board has much nicer standby power draw, about 4.5mA (or about a month total standby time):
Overall a win, but it'd still be nice if the pommel shroud's hole was placed better.
Also, an update on my green saber. Today it got hit pretty hard and the blade light went out. I immediately took it apart to find out why, and discovered that the
other side of the emitter resistor had broken free from its wire. So I soldered it back together and it's fine now, but the resistor connection is apparently pretty brittle. Both sides of it broke and had to be repaired, even with heat shrink protecting it.
When I put it back together I routed the wires extra-carefully, which allowed the LED to sit deeper in the hilt. This makes my new green day blade look better (it had glue a bit high inside, which looked weird through the windows, but now it's mostly hidden) and makes the blade plug fit without trimming.
Oh, and in case I forgot to mention it before, I upgraded my saber a couple weeks ago with a charge port and lighted switch. This makes it much nicer overall.
I think I've decided not to weather the hilt because I have a weathered Gladius now. The pair looks better with one being shiny. Hopefully I'll have time to get and share some decent pictures soon.