Just an update on this project. I decided to install a Plecter Labs Blaster Core v4.0 in the Hand Schaub after drooling over RedArc's for the last year. The grip/trigger portion is being fitted with a functional, replica trigger by RedArc. I spent some time this weekend creating the chassis for the electronics. I figured I would share some photos of it. I doubt this will be of much use to anyone trying to install electronics in their EE-3 because I didn't take photos from each step of the process. I only took them when I thought of it. Sorry about that. I basically built a lightsaber-esque chassis that will slide through the barrel of the Hand Schaub. The photos aren't of the finished product because I am waiting on some resistors from Mouser for my main and auxiliary leds, hence why it is taped in the midsection. The blaster core board and recharge port/kill switch will be attached at the end. I'll post up some test videos once I install the resistors. I used a bunch of parts I already had from old lightsaber projects, as well as cannibalized parts from old hard drives. This already heavy blaster is going to get a lot heavier once I'm finished. Ugh.
This is the LED housing which holds a tri-rebel mounted to a heatsink. The red and royal blue dies are being utilized. I also have a focusing lens on top of the tri-rebel to control the angle of the light. This mounts to the speaker housing you see in the image which is mounted via 4-40 threaded rods sheathed in brass tubing.
Here is a side view with part of the batter chamber exposed. I used some parts I purchased from the custom saber shop years ago. The upper compartment holds two 18650 Li-Ion batteries for 7.4v as well as the wires from the front speaker and tri-rebel.
Same thing, only from a different angle.
This is the rear speaker housing and speaker. The housing is a hard drive part that has a strong magnetic ring on it which holds the speaker firmly in place. Pretty convenient. This speaker is rear-facing and is mounted in the lower compartment with the Blaster Core, recharge port, and soon to be LED bargraph.
Here is an image of the rear portion of the battery chamber. The nuts will match on the finished product (not that it matters. No one will ever see it, lol.)
This was the basic layout of the rear chamber (minus the recharge port and bargraph). The rear speaker is compression fitted in the tube.
Just another angle of the setup.
A closer shot of the LED housing mounted to the front speaker housing. I'm just using electrical tape. It suits my needs. Surprisingly the speaker is still loud as hell, as well as clear. The copper heatsink does have 6 holes drilled in it to accommodate multi-die LEDs so that's probably helping a lot.
A view into the rear chamber. Nothing is fastened down yet but you can see that I will have easy access to the micro SD card in case I want to adjust soundfonts or configuration files on the board. Things will be fixed to the sides of the chamber. Once I get my custom bargraph as well as the grip section back from RedArc, I'll put everything in place. You can see the rear-facing speaker in the back. This will be the view when you open that blaster on its hinge.
Last photo. This is essentially what the finished product will look like. I plan on getting a male-male adapter to connect the two tubes, but I just have electrical tape there for now. Who knows, I may just use electrical tape in the end. The chassis will be compression fitted once I put the Heiland tube on in the front and I plan on hot gluing the rear portion of the tube. As you can see, the whole thing will slide through the barrel of the EE-3. I am working out a solution to getting the auxiliary switch installed in the space behind the front battery housing. I've got an idea in mind for it though so I'm not too worried.
Well that's about it for now. Once I install the resistors I'll make a test video for sound and lights. Thanks so much to RedArc for installing the functional trigger for me. Can't wait to get this completed. Let me know what you think.
**Edit** I forgot to add a few pics of the chassis inside the barrel. Here you go: