I made this Halo energy sword for my nephew for his birthday. I decided on using an electronic sword to start with because it already had lights, sound and was motion activated. I found a really good one at Toys R Us for 11 bucks. Not bad. I first created my template in the computer plotted it full size. I made it only 21.5" to more closely match the scale of my nephew. I transferred my pattern to 1/4" MDF and cut it out as accurately as I could. I used the wooden template to cut the plexiglass using a flush trim bit on the router table. I sanded one side of the plexi with an orbital sander and 200 grit sandpaper so it would catch the light. I also polished the edges hoping to keep more light in.
I used the same template to cut the handle shape so it would match with much less work. After that I shaped the handles as well as I could with the dremel and cut all of the pockets for the circuit board, speaker, button, on/off switch and LEDs. The sword handles do not match the game as I decided to place some of the handle over the blades to hide the LEDs. I placed all of the electronics and battery pack in the wooden handles. And epoxied it all together. I wish the sword had come with more LEDs, only facing one forward on each half doesn't quite seem sufficient. Next sword more lights :). After the wooden part was complete, I added a sintra battery cover. Then some more details using Apoxie clay. Not too happy with this step as I screwed up and ended up with a gimongous line around the battery compartment. Then the paint and it was all ready for shipping. Over all I was really really happy with it. Fun as hell to swing around.
I'll definitely do a second version. I want to clay the entire handle next time and try to cast from that to make multiple handles for friends. I also think I'll use the same sword again for it's sound and motion activation. I've seen a really nice energy sword using EL wire but I think I'm gonna stick with the LEDs unless I get a bug to try for the sound, motion and EL, who knows, as lazy as I am I may never get around to it at all.
Check out the video HERE. (1 mb)