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?