In an increasingly paperless society, writing implements are becoming an obsolete for many of us. Certainly not the kind of thing the average person would think to spend more than a couple bucks on, to say nothing of machining one out of a solid piece of aluminum bar stock. But clearly [Bob] is not most people. He recently dropped us a line about a video he uploaded to his aptly-named YouTube channel “Making Stuff”, where he goes through the steps required to turn raw materials into a writing instrument worthy of a Jedi.

Starting with a piece of aluminum chucked up in the lathe, [Bob] cuts out the iconic ribbed profile of Luke’s saber and fills in the gaps with nothing more exotic than a black Sharpie. He then moves on to the more complex shape of the emitter, and then flips the handle over in the lathe and hollows it out so a brass tube can be inserted.

Turning down the acrylic “blade”

Somewhat surprisingly, it seems more effort ends up being put into the acrylic “blade” than the aluminum handle itself. A chunk of acrylic is drilled and tapped so that it can be mounted in the chuck, and then turned down into a long cylinder. A tip is then cut in the end, the length of the blade is hollowed out, and finally it gets polished up to a nice shine.

The build is completed by inserting a standard ink pen cartridge down the center of the now completed saber. Surely the pen aficionados will lament that he didn’t attempt to build his own ink cartridge as well, but we think he gets a pass considering the rest of it was made from scratch.

If even a glorious writing instrument such as this isn’t enough to get you to re-learn how to write your name, fear not. Whether you’re making music or capturing flags, we’ve played to numerous other saber projects; eye-safe or otherwise.



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