Hold on Nutcore, more diagrams are coming…
Sorry for the break everyone, and thanks for all the support! Ok, I’m no draftsman, but I hope this gives everyone a start on the clear plastic part. As with any dimensions I provide, they’re all pretty flexible since we’re not dealing with tolerances on the space shuttle or anything. Band saws, table saws, they’re not precision cutting tools. Allow plenty of room to “sneak up” on the right dimensions. Make the dimensions work for you…each one of these RFs quickly turns into a one-off custom part. The disc sander allows a lot of guess work to become perfection. Don’t try to make the perfect cut the first time. Go slowly. A pencil line can always be erased from either the plastic or the contact paper.
Which ever part you choose to make, remember how it’s going to fit into the RF. The ESB part mounts proudly in the RF while the ROTJ part is tucked somewhat. Notice the ROTJ version vertex is just barely inside the RF's underside curve. Reference, reference, reference! If you combine the Hyperdyne kit and the ROTJ clear version, you’ll have to make your own guess as to making the inside[back] cuts since I haven’t made a Jedi version with the Hyperdyne kit yet. Yet don’t anticipate a loose fit for anything…that’s the whole idea, it’s supposed to be tight.
Even if you had this kind of part machined by a custom plastics company, not only might it become very pricey, but I think you might lose some of the finish from hand sanding that makes this piece so believable.
If you do attempt this project, feel free to PM me with questions. It took a lot of experimenting to get this far...I’ve gone through all the R&D so you don’t have to.
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