How to Make a 4ft Toy Lightsaber

These are slow and heavy, but are fun and great for beginners!

Everything you need for your little venture should be readily available at your local Home Depot (we love you Home Depot!) or similar local hardware store.

• 1x ½" x 48"  pvc nipple threaded pipe  ~$2.00
• 1x ½ foam pipe insulation wrap. Sold in 6ft. lengths. Make sure it fits tight!  ~$1.00
• 1x 1½" plumbing coupler. Make sure its flared at one end.  ~$6.00
• 1x 1½" threaded plumbing adapter that screws on to the end of the pipe and is slightly larger than the coupler.  ~$1.00
• 1x roll of colored duct tape, this is the color your sword will be.  ~$5.00
• 1x roll of non slide grip tape (stuff on stairs, boats, and stuff). Five yard roll  ~$4.00 - $5.00

Now that you have all of your supplies, you can start to assemble your new lightsaber!

• First, start by slowly pushing the foam down around the plastic pipe. DO NOT pop it open at the seam to make it easier to put on. This will make a gap in the foam if its not taped back together right and you may hurt someone. While putting on the foam, it often helps to twist and pull. This will avoid splits in the perforated seam, and it will slip down the pipe easier.

  

• Pull the foam down so that there is about 4-5 inches between the bottom of the foam and the bottom of the pipe. Once the foam is in place, cut off the extra leaving about 2 inches sticking above the top of the pipe. This will be folded over the tip to keep from impaling your friends when you...stab them.
• Now take the colored duct-tape and start at the bottom and wrap up. This will give the foam strength and give your 'lightsaber' a color. While wrapping it with duct tape, it is best to do so at a spiraling angle. (Yes, I know I'm using regular duct tape not colored)

  

• When you get to the end with the extra foam, fold it over and put a few pieces of tape over the top (coming down a few inches on either side) to hold it down. Then wrap around the pipe near the top to finish it off.

  

• One last taping thing to do. "Why" you ask, "did we leave five inches at the bottom??" I'll tell you. Start a few inches up on the foam and wrap downward tightly past the bottom of the foam onto the pvc pipe. Stop right before you get to the threads on the bottom. This will ensure that the foam will not slide up.

  

• Once completely wrapped, it is time to put your handle on. Get the metal coupler you bought and shove it on the end opposite of the "squishy tip." To make it easier to get on, it works best to have a coupler that is flanged, so that there is a wider opening coming into a smaller pipe. This end would logically go in first. Slide it on until all the threads are visible below the bottom of the coupler. Now screw the flared plumbing adapter on tight then slide the handle as far down as it will go.
• Now, if you wish to add some grip to your handle, get some of the walking grip-tape they use on boats and steps (use something more "gentle" if you wish). Cut it into a desired shape that feels good on your hands and stick it down. Make sure all edges are down otherwise it tends to peel up and be worse than no grip at all.

Have fun!