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Star Wars

Luke Skywalker’s Lightsaber

Created by
Dustin McLean
Build time
1 day
Budget
<$100
Skill level
Intermediate
Description

Make Luke Skywalker’s lightsaber out of junk materials you might have around at home. It’s one of the most iconic movie props of all time, based off of a flash bulb from an antique camera. This version is taken from Luke’s original lightsaber given to him by Obi-Wan Kenobi (and made by Anakin).

Tools required

• Small hacksaw (example here)

• Rotary toolkit (example here)

• Sandpaper

• Metal File (heavy-grit sandpaper would work instead)

• Hot glue gun

• Drill (example here)

• Superglue

• Scissors

• Exacto knife

• Permanent pen

• Medium paint brush or sponge brush

skills required

• Ability to handle sharp tools

• Safely use a glue gun

• Find a parent if you’re under 13

images for inspiration
No images available
Supply list

Below is a list of all parts used to make this costume. In case you don’t already have them, we’ve included purchase links. Note the estimated cost reflects the cost of a full package (e.g. you may only need 5 screws, but the cost is for a large pack them).

Part Description
Costume section
est. Cost
Part description
1 sink tailpiece (white, plastic 1.5in wide, 12in long)
costume section
Basic hilt shape
Est. Cost
$2.00
Part description
1 1-inch PVC pipe, 3 inches long
costume section
Basic hilt shape
Est. Cost
$4.00
Part description
1 sprinkler head
costume section
Basic hilt shape
Est. Cost
$3.30
Part description
Thin craft foam 2mm (12x18” sheet)
costume section
Basic hilt shape
Est. Cost
$1.00
Part description
1 pipe strap 3/8-inch
costume section
Basic hilt shape
Est. Cost
$9.00 (for 30-pack)
Part description
2 grip rivnuts 1/4-inch
costume section
Buttons
Est. Cost
$8.00 (for 30-pack)
Part description
Screws
costume section
Multiple sections
Est. Cost
$11.00 (assortment)
Part description
Wiggly eyes
costume section
Buttons
Est. Cost
$1.00 (42-pack)
Part description
Spray paint - red
costume section
Buttons
Est. Cost
$4.00
Part description
D-Ring
costume section
Base
Est. Cost
$10.00 (120-pack)
Part description
Scrap plastic / craft plastic
costume section
Base
Est. Cost
$10.50 (20-pack)
Part description
Thick craft foam, 6mm
costume section
Base
Est. Cost
$1.00
Part description
Gray primer
costume section
Base
Est. Cost
$4.00
Part description
Silver metallic spray paint
costume section
Base
Est. Cost
$4.00
Part description
Gorilla tape
costume section
Middle strap
Est. Cost
$9.00
Part description
Bronze duct tape
costume section
Middle strap
Est. Cost
$8.00
Part description
Picture hanger
costume section
Middle strap
Est. Cost
$2.30
Part description
Masking tape
costume section
Paint
Est. Cost
$4.00
Part description
Copper wire 12-gauge (alt: toothpick pieces)
costume section
Side sockets
Est. Cost
$10.00
Part description
PVA craft glue (alt: school glue)
costume section
Grips
Est. Cost
$18.00 (3-pack)
Part description
Flat black spray paint
costume section
Grips
Est. Cost
$4.00
Guide

Basic Hilt Shape (1:54):

  • Cut the Sink Tailpiece down to 11 inches using a small hacksaw.
  • Draw the curved tip using reference photos.
  • Cut the curved tip using a rotary tool, and the rough edge.
  • I would skip ahead to 6:51 in the video and do this next step here instead! Drill a 3/4-inch hole on both sides of the hilt either using a large drill bit or a rotary tool.
  • Unscrew the top of the sprinkler head and file the threads to fit into the 1 inch PVC pipe (if needed) and place it into 1 inch PVC snugly.
  • Insert the PVC pipe into the curved end of the Sink Tailpiece using a small piece of thin craft foam (or cardboard) wrapped around it to make it fit snugly. Secure with hot glue.

Side Clips (2:44):

  • Cut the two sides off of a pipe strap using a hacksaw.
  • You can glue these into place as-is or create a more sturdy connection like I did in the video by using a small piece of scrap metal to brace these onto the plastic more securely.

Buttons (3:14):

  • Drill 2 small pilot holes then attach the 2 Rivnuts using small machine screws (whatever best fits your rivnuts) along with a tiny bit of superglue if needed.
  • Paint 2 of the Wiggly Eyes with red spray paint.
  • Set aside for later.

Base (4:08):

  • Trace the bottom of the Sink Tailpiece onto a scrap piece of plastic (such as a plastic lid) and cut the circle out with scissors.
  • Cut a small rectangle out of the Thick Craft Foam to make a brace piece, leaving a small space for the D-Ring. Glue onto the plastic disc with one of the medium-small D-Rings in place.
  • Screw 2 tiny machine screws into the foam for an added detail.
  • Paint with Gray Primer, let dry.
  • Paint with Silver Metallic Spray Paint, let dry.
  • Glue into the open end of the hilt.

Middle Strap (5:32):

  • Wrap a piece of tape around the center (I used 2 layers of thick Gorilla Tape but you could use several more layers of regular Duct Tape or Masking Tape) using the full 2-inch width.
  • Wrap another layer in the middle 1/2-inch wide.
  • DIY ALERT! You’ll have to get creative with this rectangular plastic piece. I used an old piece of scrap plastic so see what misc junk you can find that might work! Or you could cut out a few pieces of craft foam to make the shape.
  • Cut a strip of Copper Duct Tape (or anything somewhat copper-colored) using an Exacto Knife or Scissors. Draw the line details with a permanent pen and attach it to the top of the rectangular piece.
  • Attach this finished rectangular piece to the strap with Super Glue.
  • Modify a Picture Hanger slightly and attach with Super Glue. (I also added one more tiny screw into it just to make it interesting.)

Side Sockets (6:04):

  • If you didn’t already do it at the beginning: Drill a 3/4-inch hole on both sides of the hilt either using a large drill bit or a rotary tool.

Paint: (6:42):

  • Mask off the bronze/copper strip on the side strap with masking tape.
  • Paint the entire thing with Gray Primer, let dry.
  • Paint the entire thing with Silver Metallic Spray Paint, let dry.
  • Remove masking tape.
  • Attach the 2 red Wiggly Eyes to the buttons with super glue.

Side sockets (7:51):

  • Inside each socket, drill 2 pilot holes with a small drill bit (depending on your wire thickness) on the inside PVC pipe.
  • Place a small piece of Copper Wire into each hole with Super Glue. (I had some extra copper wire to use but you could use any old, thich wire or even pieces of toothpick).

Grips (9:21):

  • There are 6 grip pieces. (Using my basic ruler I found that they were 1.5 centimeters wide each with a .5 centimeter space between each.)
  • Using the Exacto Knife, cut 6 strips out of Thin Craft Foam, 1.5 cm wide and 10.5 cm long.
  • Cut 6 more small strips .5 cm wide and 7.5 cm long.
  • Cut 6 more tiny strips .5 cm wide and 1 cm long.
  • Glue the small and tiny strips (with a gap) perpendicularly down the center of the larger strips using Super Glue.
  • Coat with PVA Craft Glue (regular School Glue could work too), let dry.
  • Paint with Flat Black Spray Paint.
  • Attach to the hilt with Hot Glue.
  • Drill small pilot holes and screw 6 small screws into the gaps.
  • I also screwed one more of those small screws into the hilt above one of the buttons.
Guide

Basic Hilt Shape (1:54):

  • Cut the Sink Tailpiece down to 11 inches using a small hacksaw.
  • Draw the curved tip using reference photos.
  • Cut the curved tip using a rotary tool, and the rough edge.
  • I would skip ahead to 6:51 in the video and do this next step here instead! Drill a 3/4-inch hole on both sides of the hilt either using a large drill bit or a rotary tool.
  • Unscrew the top of the sprinkler head and file the threads to fit into the 1 inch PVC pipe (if needed) and place it into 1 inch PVC snugly.
  • Insert the PVC pipe into the curved end of the Sink Tailpiece using a small piece of thin craft foam (or cardboard) wrapped around it to make it fit snugly. Secure with hot glue.

Side Clips (2:44):

  • Cut the two sides off of a pipe strap using a hacksaw.
  • You can glue these into place as-is or create a more sturdy connection like I did in the video by using a small piece of scrap metal to brace these onto the plastic more securely.

Buttons (3:14):

  • Drill 2 small pilot holes then attach the 2 Rivnuts using small machine screws (whatever best fits your rivnuts) along with a tiny bit of superglue if needed.
  • Paint 2 of the Wiggly Eyes with red spray paint.
  • Set aside for later.

Base (4:08):

  • Trace the bottom of the Sink Tailpiece onto a scrap piece of plastic (such as a plastic lid) and cut the circle out with scissors.
  • Cut a small rectangle out of the Thick Craft Foam to make a brace piece, leaving a small space for the D-Ring. Glue onto the plastic disc with one of the medium-small D-Rings in place.
  • Screw 2 tiny machine screws into the foam for an added detail.
  • Paint with Gray Primer, let dry.
  • Paint with Silver Metallic Spray Paint, let dry.
  • Glue into the open end of the hilt.

Middle Strap (5:32):

  • Wrap a piece of tape around the center (I used 2 layers of thick Gorilla Tape but you could use several more layers of regular Duct Tape or Masking Tape) using the full 2-inch width.
  • Wrap another layer in the middle 1/2-inch wide.
  • DIY ALERT! You’ll have to get creative with this rectangular plastic piece. I used an old piece of scrap plastic so see what misc junk you can find that might work! Or you could cut out a few pieces of craft foam to make the shape.
  • Cut a strip of Copper Duct Tape (or anything somewhat copper-colored) using an Exacto Knife or Scissors. Draw the line details with a permanent pen and attach it to the top of the rectangular piece.
  • Attach this finished rectangular piece to the strap with Super Glue.
  • Modify a Picture Hanger slightly and attach with Super Glue. (I also added one more tiny screw into it just to make it interesting.)

Side Sockets (6:04):

  • If you didn’t already do it at the beginning: Drill a 3/4-inch hole on both sides of the hilt either using a large drill bit or a rotary tool.

Paint: (6:42):

  • Mask off the bronze/copper strip on the side strap with masking tape.
  • Paint the entire thing with Gray Primer, let dry.
  • Paint the entire thing with Silver Metallic Spray Paint, let dry.
  • Remove masking tape.
  • Attach the 2 red Wiggly Eyes to the buttons with super glue.

Side sockets (7:51):

  • Inside each socket, drill 2 pilot holes with a small drill bit (depending on your wire thickness) on the inside PVC pipe.
  • Place a small piece of Copper Wire into each hole with Super Glue. (I had some extra copper wire to use but you could use any old, thich wire or even pieces of toothpick).

Grips (9:21):

  • There are 6 grip pieces. (Using my basic ruler I found that they were 1.5 centimeters wide each with a .5 centimeter space between each.)
  • Using the Exacto Knife, cut 6 strips out of Thin Craft Foam, 1.5 cm wide and 10.5 cm long.
  • Cut 6 more small strips .5 cm wide and 7.5 cm long.
  • Cut 6 more tiny strips .5 cm wide and 1 cm long.
  • Glue the small and tiny strips (with a gap) perpendicularly down the center of the larger strips using Super Glue.
  • Coat with PVA Craft Glue (regular School Glue could work too), let dry.
  • Paint with Flat Black Spray Paint.
  • Attach to the hilt with Hot Glue.
  • Drill small pilot holes and screw 6 small screws into the gaps.
  • I also screwed one more of those small screws into the hilt above one of the buttons.
Description

Make Luke Skywalker’s lightsaber out of junk materials you might have around at home. It’s one of the most iconic movie props of all time, based off of a flash bulb from an antique camera. This version is taken from Luke’s original lightsaber given to him by Obi-Wan Kenobi (and made by Anakin).

Tools required

• Small hacksaw (example here)

• Rotary toolkit (example here)

• Sandpaper

• Metal File (heavy-grit sandpaper would work instead)

• Hot glue gun

• Drill (example here)

• Superglue

• Scissors

• Exacto knife

• Permanent pen

• Medium paint brush or sponge brush

skills required

• Ability to handle sharp tools

• Safely use a glue gun

• Find a parent if you’re under 13

images for inspiration
No images available
Supply list

Below is a list of all parts used to make this costume. In case you don’t already have them, we’ve included purchase links. Note the estimated cost reflects the cost of a full package (e.g. you may only need 5 screws, but the cost is for a large pack them).

Part Description
Costume section
est. Cost
Part description
1 sink tailpiece (white, plastic 1.5in wide, 12in long)
costume section
Basic hilt shape
Est. Cost
$2.00
Part description
1 1-inch PVC pipe, 3 inches long
costume section
Basic hilt shape
Est. Cost
$4.00
Part description
1 sprinkler head
costume section
Basic hilt shape
Est. Cost
$3.30
Part description
Thin craft foam 2mm (12x18” sheet)
costume section
Basic hilt shape
Est. Cost
$1.00
Part description
1 pipe strap 3/8-inch
costume section
Basic hilt shape
Est. Cost
$9.00 (for 30-pack)
Part description
2 grip rivnuts 1/4-inch
costume section
Buttons
Est. Cost
$8.00 (for 30-pack)
Part description
Screws
costume section
Multiple sections
Est. Cost
$11.00 (assortment)
Part description
Wiggly eyes
costume section
Buttons
Est. Cost
$1.00 (42-pack)
Part description
Spray paint - red
costume section
Buttons
Est. Cost
$4.00
Part description
D-Ring
costume section
Base
Est. Cost
$10.00 (120-pack)
Part description
Scrap plastic / craft plastic
costume section
Base
Est. Cost
$10.50 (20-pack)
Part description
Thick craft foam, 6mm
costume section
Base
Est. Cost
$1.00
Part description
Gray primer
costume section
Base
Est. Cost
$4.00
Part description
Silver metallic spray paint
costume section
Base
Est. Cost
$4.00
Part description
Gorilla tape
costume section
Middle strap
Est. Cost
$9.00
Part description
Bronze duct tape
costume section
Middle strap
Est. Cost
$8.00
Part description
Picture hanger
costume section
Middle strap
Est. Cost
$2.30
Part description
Masking tape
costume section
Paint
Est. Cost
$4.00
Part description
Copper wire 12-gauge (alt: toothpick pieces)
costume section
Side sockets
Est. Cost
$10.00
Part description
PVA craft glue (alt: school glue)
costume section
Grips
Est. Cost
$18.00 (3-pack)
Part description
Flat black spray paint
costume section
Grips
Est. Cost
$4.00
Guide

Basic Hilt Shape (1:54):

  • Cut the Sink Tailpiece down to 11 inches using a small hacksaw.
  • Draw the curved tip using reference photos.
  • Cut the curved tip using a rotary tool, and the rough edge.
  • I would skip ahead to 6:51 in the video and do this next step here instead! Drill a 3/4-inch hole on both sides of the hilt either using a large drill bit or a rotary tool.
  • Unscrew the top of the sprinkler head and file the threads to fit into the 1 inch PVC pipe (if needed) and place it into 1 inch PVC snugly.
  • Insert the PVC pipe into the curved end of the Sink Tailpiece using a small piece of thin craft foam (or cardboard) wrapped around it to make it fit snugly. Secure with hot glue.

Side Clips (2:44):

  • Cut the two sides off of a pipe strap using a hacksaw.
  • You can glue these into place as-is or create a more sturdy connection like I did in the video by using a small piece of scrap metal to brace these onto the plastic more securely.

Buttons (3:14):

  • Drill 2 small pilot holes then attach the 2 Rivnuts using small machine screws (whatever best fits your rivnuts) along with a tiny bit of superglue if needed.
  • Paint 2 of the Wiggly Eyes with red spray paint.
  • Set aside for later.

Base (4:08):

  • Trace the bottom of the Sink Tailpiece onto a scrap piece of plastic (such as a plastic lid) and cut the circle out with scissors.
  • Cut a small rectangle out of the Thick Craft Foam to make a brace piece, leaving a small space for the D-Ring. Glue onto the plastic disc with one of the medium-small D-Rings in place.
  • Screw 2 tiny machine screws into the foam for an added detail.
  • Paint with Gray Primer, let dry.
  • Paint with Silver Metallic Spray Paint, let dry.
  • Glue into the open end of the hilt.

Middle Strap (5:32):

  • Wrap a piece of tape around the center (I used 2 layers of thick Gorilla Tape but you could use several more layers of regular Duct Tape or Masking Tape) using the full 2-inch width.
  • Wrap another layer in the middle 1/2-inch wide.
  • DIY ALERT! You’ll have to get creative with this rectangular plastic piece. I used an old piece of scrap plastic so see what misc junk you can find that might work! Or you could cut out a few pieces of craft foam to make the shape.
  • Cut a strip of Copper Duct Tape (or anything somewhat copper-colored) using an Exacto Knife or Scissors. Draw the line details with a permanent pen and attach it to the top of the rectangular piece.
  • Attach this finished rectangular piece to the strap with Super Glue.
  • Modify a Picture Hanger slightly and attach with Super Glue. (I also added one more tiny screw into it just to make it interesting.)

Side Sockets (6:04):

  • If you didn’t already do it at the beginning: Drill a 3/4-inch hole on both sides of the hilt either using a large drill bit or a rotary tool.

Paint: (6:42):

  • Mask off the bronze/copper strip on the side strap with masking tape.
  • Paint the entire thing with Gray Primer, let dry.
  • Paint the entire thing with Silver Metallic Spray Paint, let dry.
  • Remove masking tape.
  • Attach the 2 red Wiggly Eyes to the buttons with super glue.

Side sockets (7:51):

  • Inside each socket, drill 2 pilot holes with a small drill bit (depending on your wire thickness) on the inside PVC pipe.
  • Place a small piece of Copper Wire into each hole with Super Glue. (I had some extra copper wire to use but you could use any old, thich wire or even pieces of toothpick).

Grips (9:21):

  • There are 6 grip pieces. (Using my basic ruler I found that they were 1.5 centimeters wide each with a .5 centimeter space between each.)
  • Using the Exacto Knife, cut 6 strips out of Thin Craft Foam, 1.5 cm wide and 10.5 cm long.
  • Cut 6 more small strips .5 cm wide and 7.5 cm long.
  • Cut 6 more tiny strips .5 cm wide and 1 cm long.
  • Glue the small and tiny strips (with a gap) perpendicularly down the center of the larger strips using Super Glue.
  • Coat with PVA Craft Glue (regular School Glue could work too), let dry.
  • Paint with Flat Black Spray Paint.
  • Attach to the hilt with Hot Glue.
  • Drill small pilot holes and screw 6 small screws into the gaps.
  • I also screwed one more of those small screws into the hilt above one of the buttons.

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