I made this Halo energy sword for my nephew for his birthday.  I decided on using an electronic sword to start with because it already had lights, sound and was motion activated.  I found a really good one at Toys R Us for 11 bucks.  Not bad.  I first created my template in the computer plotted it full size.  I made it only 21.5" to more closely match the scale of my nephew.  I transferred my pattern to 1/4" MDF and cut it out as accurately as I could.  I used the wooden template to cut the plexiglass using a flush trim bit on the router table.  I sanded one side of the plexi with an orbital sander and 200 grit sandpaper so it would catch the light.  I also polished the edges hoping to keep more light in.

I used the same template to cut the handle shape so it would match with much less work.  After that I shaped the handles as well as I could with the dremel and cut all of the pockets for the circuit board, speaker, button, on/off switch and LEDs.  The sword handles do not match the game as I decided to place some of the handle over the blades to hide the LEDs.  I placed all of the electronics and battery pack in the wooden handles.  And epoxied it all together.  I wish the sword had come with more LEDs, only facing one forward on each half doesn't quite seem sufficient.  Next sword more lights :).  After the wooden part was complete, I added a sintra battery cover.  Then some more details using Apoxie clay.  Not too happy with this step as I screwed up and ended up with a gimongous line around the battery compartment.  Then the paint and it was all ready for shipping.  Over all I was really really happy with it.  Fun as hell to swing around.

I'll definitely do a second version.  I want to clay the entire handle next time and try to cast from that to make multiple handles for friends.  I also think I'll use the same sword again for it's sound and motion activation.  I've seen a really nice energy sword using EL wire but I think I'm gonna stick with the LEDs unless I get a bug to try for the sound, motion and EL, who knows, as lazy as I am I may never get around to it at all.

Check out the video HERE.  (1 mb)

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