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  1. Dessel's Avatar
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    Jul 6, 2007, 10:20 PM - Zannah's Weaponry #1

    Well, here it is, the progress page for my work on Zannah's (my girlfriend) armory. Separate from the armor itself, this will track the work I've done on the design of her replica and original weapons.

    The first project is the lightsaber of her design. So far, I'll be working off of this sketch (click for larger version):


    I'm honestly not sure of what base material I want to use. I have a little experience doing these things with PVC pipe, but I'm not sure that such would be the best choice due to the concave nature of the hilt. Because I'm looking to get into Sintra molding and vacuum forming anyway, I'm wondering if that might be a better way to go about the shell of this design.

    I am perfectly fine with doing all of my own research, and will be doing just that, but I would definitely appreciate any advice and recommendations that you may offer.

    That being said, has anyone had much luck with vacuum forming or Sintra molding the shell of a lightsaber hilt, or is some other technique superior?

    Thanks! Enjoy!
    Last edited by Dessel; Jul 7, 2007 at 5:33 PM.
  2. Kyram's Avatar
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    Jul 6, 2007, 10:38 PM - Re: Zannah's Armory #2

    If you're going to go the sintra/plastic route you could always start with a PVC plumbing tube as a base. Then you could use peices of sintra and bondo to craft the details.
  3. Dessel's Avatar
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    Jul 6, 2007, 10:43 PM - Re: Zannah's Armory #3

    Quote Kyram said: View Post
    If you're going to go the sintra/plastic route you could always start with a PVC plumbing tube as a base. Then you could use peices of sintra and bondo to craft the details.
    I was just giving thought to that. Thanks.
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    Jul 6, 2007, 10:57 PM - Re: Zannah's Armory #4

    Thanks for the advice. I really need to finish that drawing...make that skull look better, for one, and figure out how to do that texture on the lower end of it.

    Plus, I have more pieces to design.
  5. Darasuum_Verd's Avatar
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    Jul 7, 2007, 1:16 AM - Re: Zannah's Armory #5

    it looks good so far

    just make sure to live up to the name, I expect much from someone with a Sithy name

    can't wait to see how this ends up!
  6. Dessel's Avatar
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    Jul 7, 2007, 1:35 AM - Re: Zannah's Armory #6

    Quote Zannah said: View Post
    Plus, I have more pieces to design.
    Speaking of which. Here is the first draft of her complimentary lightsaber hilt (click for a larger view):



    It seems that, with names like Dessel and Zannah, we do have quite the reputation to live up to. But if I'm crafting these things for Zannah, surely I cannot help but create the finest of goods, right?

    Thanks for the interest.
  7. Darth Valcar's Avatar
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    Jul 7, 2007, 3:32 AM - Re: Zannah's Armory #7

    Quote Dessel said: View Post
    Speaking of which. Here is the first draft of her complimentary lightsaber hilt (click for a larger view):



    It seems that, with names like Dessel and Zannah, we do have quite the reputation to live up to. But if I'm crafting these things for Zannah, surely I cannot help but create the finest of goods, right?

    Thanks for the interest.
    Looks great will you be making this a lights and sound saber ?
  8. I helped at SDCC '08 NovallTalon's Avatar
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    Jul 7, 2007, 9:44 AM - Re: Zannah's Armory #8

    Looking good, those are some awesome designs! Someone is a good drawer I see =D
  9. jodo's Avatar
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    Jul 7, 2007, 11:06 AM - Re: Zannah's Armory #9

    I think I would use a peice of PVC as a base, and then build it up from there so it will be easier/study. For the first saber you posted, you may try putting bigger peices of PVC on top of it and then using bondo to build up into them for the slant/coke bottle shape.

    For the second saber, you might also try using PVC, if you go to Lowe's,etc. You be able to find some angled peices,etc. thats how I did my old saber. I also used some round soft "things".
    Its also how I did my small explosive device. -


  10. Member Since
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    Jul 7, 2007, 11:48 AM - Re: Zannah's Armory #10

    Quote jodo said: View Post
    I think I would use a peice of PVC as a base, and then build it up from there so it will be easier/study. For the first saber you posted, you may try putting bigger peices of PVC on top of it and then using bondo to build up into them for the slant/coke bottle shape.

    For the second saber, you might also try using PVC, if you go to Lowe's,etc. You be able to find some angled peices,etc. thats how I did my old saber. I also used some round soft "things".
    Its also how I did my small explosive device. -
    Thanks for the advice. I don't remember seeing pieces curved like that anywhere, merely corner ones, but I'll have to look. I was thinking of using some sort of foam or something for the grip on the first one, but I'm not certain yet.

    Thanks for all the compliments as well. Now...hmm...set of blaster pistols and the armor to design. Guess I'll be busy.
  11. Dessel's Avatar
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    Jul 8, 2007, 7:46 PM - Re: Zannah's Armory #11

    Quote Zannah said: View Post
    Thanks for all the compliments as well. Now...hmm...set of blaster pistols and the armor to design. Guess I'll be busy.
    Blaster pistols? Let's see what I can dig up.

    Oh, what's that? A new sketch?

    Yes, here's Zannah's latest sketch for a blaster pistol:


    Does anyone have any recommendations for what to use as a base for this? The near-right angle leads me to think that the NES Zapper won't be a perfect base. Anyway, any recommendations would be appreciated!
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    Jul 8, 2007, 8:05 PM - Re: Zannah's Armory #12

    Well, I still need to find some pvc for the lightsabers...there are some dowel things laying around that are about the right size, as well.
  13. eighteendelta's Avatar
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    Jul 8, 2007, 9:53 PM - Re: Zannah's Armory #13

    Quote Dessel said: View Post
    Blaster pistols? Let's see what I can dig up.

    Oh, what's that? A new sketch?

    Yes, here's Zannah's latest sketch for a blaster pistol:


    Does anyone have any recommendations for what to use as a base for this? The near-right angle leads me to think that the NES Zapper won't be a perfect base. Anyway, any recommendations would be appreciated!
    Cut it out of fiberboard or hardboard and build it up from there.

    -x
  14. Dessel's Avatar
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    Jul 9, 2007, 3:14 AM - Re: Zannah's Armory #14

    Quote eighteendelta said: View Post
    Cut it out of fiberboard or hardboard and build it up from there.

    -x
    Sounds like a plan. Thanks.

    I spent a little time working on Zannah's straight/tapered saber hilt earlier. I started by trying to adapt a simple sparring hilt I created previously, but I felt it was too bulky and just not right. I took another, smaller, piece of PVC pipe and worked on building it up from there.

    The material I'm using for building this up is a form of the plastic signboard, but this is corrugated, and I don't think that's what I want to be using in the long run. Still, for prototyping, it seems to work.

    Here's what I've been able to do so far:


    The upper one is, visibly, the larger, bulkier version. It just isn't what I wanted it to be. The bottom one is the sleeker one, and considerably closer to the concept draft.

    Though still a ways off from the end goal, some progress has been made. I'm already finding that I enjoy hand crafting these things.

    In regards to the curved hilt, forgive my ignorance, does PVC pipe become malleable when heated? I would think this quite possible, but I'm not sure.

    Any and all feedback will be appreciated!
  15. eighteendelta's Avatar
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    Jul 9, 2007, 11:26 AM - Re: Zannah's Armory #15

    PVC does soften but it also becomes brittle and discolored when heated to reshap, especially at the thickness you are going to find in a PVC pipe. Instead of melting I would suggest using an old welders trick when using straight pipe to build a curved exhaust system. Cut out wedges in even pieces at the same angle like such...



    Forgive my poor rendition. Glue the pieces back together and sand it as smooth as you want for this project, it might even be kind of a nice texture if left without smoothing too much. Using a thicker piece of PVC pipe would work better in any case. Good luck.

    -x
    Last edited by eighteendelta; Jul 9, 2007 at 11:37 AM.
  16. Dessel's Avatar
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    Jul 10, 2007, 1:38 AM - Re: Zannah's Armory #16

    eighteendelta, I've made use of your recommendation. Thanks for taking the time to create illustrations as well!

    I used a slight variant of it, actually. I ended up using a series of inch-long segments with a flat side and an angled side. I haven't gotten a chance to go pick up real materials yet, so I'm just making due with my dremel, some PVC I had lying around, and man's best friend - duct tape.

    Here is the current build of the curved hilt:


    Alternate view:


    I admit, again, I'm pretty new to crating things like this. How would you recommend creating the wedges in your illustration (as in, what tool would you use)? I referenced a dremel, and that's what I used to do this, but it's not really looking like the optimal tool for the job.

    Thanks!
  17. eighteendelta's Avatar
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    Jul 10, 2007, 8:27 AM - Re: Zannah's Armory #17

    A bandsaw or scroll saw seem to be the best option in my mind. Don't worry if your edges aren't perfect at first, just cut the wedges, then lay some sandpaper on a hard flat surface and sand your joining surfaces flat. Looks like you got a good start already.

    -x
  18. Dessel's Avatar
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    Jul 16, 2007, 9:03 PM - Re: Zannah's Armory #18

    Thanks for the tip, eighteendelta.

    We made some progress on the straight hilt today, so here is what we currently have to show for it:



    Some of the duct tape we were using can be seen, unfortunately, but the overall progress is pleasing. I'm very impressed with this spray paint we found... it doesn't look quite like we're using a metal as the core component, but it's not too terribly far off.
  19. drokkul's Avatar
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    Jul 17, 2007, 3:38 AM - Re: Zannah's Armory #19

    You know...for the curved lightsaber you might be able to get some chrome pipe mandrel bent at a muffler shop. No creases, no seams and you would have it chrome like most all sabers.
  20. Member Since
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    Jul 25, 2007, 12:13 PM - Re: Zannah's Armory #20

    Here's how the straight hilt looks now.

  21. I helped at SDCC '08 NovallTalon's Avatar
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    Jul 25, 2007, 12:53 PM - Re: Zannah's Armory #21

    Instead of duct tape, why not use metal tape? You can get it at any auto supply store and works great to give things a metal look since its...metal! =D

    Looks like that saber would be a 2 hander that could cause some mighty big damage =D
  22. Member Since
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    Jul 25, 2007, 1:26 PM - Re: Zannah's Armory #22

    Quote NovallTalon said: View Post
    Instead of duct tape, why not use metal tape? You can get it at any auto supply store and works great to give things a metal look since its...metal! =D

    Looks like that saber would be a 2 hander that could cause some mighty big damage =D
    Duct tape...what duct tape? That all was ripped off. The handle wrapping is some of that plastic string for ballons.

    It's just a one-handed saber, actually. Sorry for the confusion...half inch PVC.

    The agled area with the skull is just cut out of a plastic ice cream bucket, and some construction adhesive holding it together in the back. The foam was cut out beforehand, from stuff taken off the shinguards used for gauntlets.
  23. I helped at SDCC '08 NovallTalon's Avatar
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    Jul 25, 2007, 1:51 PM - Re: Zannah's Armory #23

    My bad, I was reading the post above about how duct tape was used.
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    Aug 5, 2007, 9:14 PM - Re: Zannah's Armory #24

    I messed around a bit with my pistol today...yes, that's a disintegrated pen there.
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    Jul 28, 2009, 9:20 PM - Re: Zannah's Armory #25

    So...I've made some progress on the weapons as well. Though I did discover spray paint melts foam. Oops.

    The light on this actually does work.


    And, a somewhat dirty trophy.

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