Installing Blade to Hilt

Get ready to install the blade to the hilt.

Install Strip Cable to Hilt

Insert the 3-pin JST cable from the strips through the top of the hilt.

NeoPixel Cable Pass Thru Hilt

Pull the 3-pin JST cable all the way through the hilt and out the other end. It should have enough length to reach the PropMaker FeatherWing.

Installing Hilt to Coupler

Pull the 3-pin JST cable so the hilt can begin to first into the coupler.

Fit the coupler into the hilt. Reference the photo for the correct orientation.

Make sure the cable is not being kinked when fitting the hilt into the coupler.

 

Secure Hilt to Coupler

Insert and fasten an M3 x 10mm pan head machine screw. Fasten until fully tightened to secure the hilt.

Connect NeoPixel Strip to PropMaker FeatherWing

Plug in the 3-pin JST cable from the strip to the PropMaker FeatherWing.

Install Speaker into Holder

The speaker is press fitted into the speaker holder. Reference the photo for best placement.

The speaker can be removed by popping it out using the hole on the other side.

Optionally peel off the protective backing if you'd like to stick it to the speaker holder. Note: Speaker will be harder to remove once the adhesive is stuck to the surface.

Install Battery into Holder

Press the battery through the holder from the ends. Do not attempt to insert the whole battery through the clip (it has a very tight fit and could break). Once the battery is fitted into the holder it can slide into place.

Install Feather into PCB holder

With the speaker, battery and NeoPixel strips now connected, the Feather is ready to be secured to the PCB holder.

Gather up the 4x M2.5 hex nuts for securing the Feather board to the PCB holder.

Place the Feather board into the PCB holder with the screws going through the mounting holes.

Secure and Snip

Insert and fasten the M2.5 hex nuts onto the threads of the screws.

Tightly fasten the hex nuts onto the screws.

The threads must be trimmed short in order to fit through the hilt. Use flush diagonal cutters to snip the screws short.

Inside the PCB Holder

The battery cable should have plenty of wiggle room. A look through the PCB holder shows there's enough space for additional connections.

Install Speaker to Hilt

The speaker is inserted through the bottom of the hilt and pushed up inside. Use a screw driver or similar to push the speaker all the through the hilt.

Install Battery to Hilt

The wiring from the speaker, strips and button are press fitted through the slits in the battery holder. This helps manage the wires and prevent them from kinking when fitted inside the hilt.

Carefully insert the battery holder into the bottom of the hilt.

Push the battery holder all the way into the hilt.

Install PCB Holder to Hilt

Begin to insert the PCB holder into the hilt. Push the PCB holder into the hilt until its flush with the hilt. 

The ledge on the end of the PCB holder allow it to be remove from the hilt by pulling it out.

The extra lip allows you to grab hold of the PCB holder.

 

Access to Feather USB Port

The USB port on the Feather board is accessible through the bottom of the hilt.

Use the USB port to recharge the battery when it gets low.

Install Pommel

The pommel is press fitted over the bottom of the hilt.

Pull the pommel out to remove it from the hilt when its time to recharge or reprogram.

Assembled Hilt

And there we have it! The darksaber is fully assembled and ready for cosplaying.

Congratulations on your build, this is the way, and May The Force Be With You!

This guide was first published on Jan 19, 2021. It was last updated on Jan 19, 2021.

This page (Hilt Assembly) was last updated on Apr 15, 2021.

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