The game shots show two black button looking things on one of the claw shrouds, and our customer wanted a lighted switch.
I needed the tolerances around the claws to be super tight so I did it by hand, and filed each slot until they cleared and fit each claw perfectly.
I left a raised ring on the top of the emitter then turned down the shroud material to match the O.D. I machined the claws out of aluminum bar and cut slots in the emitter to mount them in. I had seen some versions out there with 4 and since our customer wanted the most accurate, we went with the 3 claw design. One thing I noticed right away is that the game saber only has 3 claws. I actually had my wife move the camera around in game while I sat right up at the TV and sketched the saber out in the different views and noted certain key design elements. So we downloaded the USE content for our TFU game and studied it in action. We've been wanting to do this saber for a while now, and had a customer from the 501st request it. I figured I would break my lurker status here and start posting some of our work.
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