Just finished my homemade lightsaber hilt!
To make a long story short; I made it for my friend, as we're planning on going to ocean city to troop, and I told him he had to have some kind of star wars costume so I won't be embarrased to be seen with him. Anyway, although this is hardly a whole costume, I figured it would be the start of a jedi/sith costume.
I used chrome-plated slip joint extensions (found in the plumbing department of your local hardware store), along w/ miscelanious other bits and THIS BASIC YOUTUBE TUTORIAL- http://www.youtube.com/watch?v=gHSVjIUml50 . this tutorial is very rough and breif, but it supplies more than enough neccesary information for forming the basic hilt design (just don't bother to whatch the goofy movie at the end). You'll see in the pics that I attached a tool-belt clip to the end of the gip, which isn't excatly the acurate saber-belt attachment design, but I'd figure it'd make for and easy-draw saber.
I would very much like to see anyone's finished saber/saber hilt. Designs are welcome as well!