How to Make a Metal Lightsaber Hilt

Updated February 21, 2017

No Star Wars costume is complete without a lightsaber. These laser swords, when not in use, are simply a hilt hanging from your belt. There are many commercially manufactured lightsabers available in stores, but these are typically made of plastic and not very well constructed. You can make a much more realistic lightsaber hilt out of metal parts found at your local hardware store. Your design is limited only by the available parts and your imagination.

Spray paint the PVC end cap black. Apply a thin coat and allow it to dry. Apply a second thin coat.

Screw the end cap onto the threaded end of the chrome pipe.

Create a grip for the lightsaber at the capped end. Use self-adhesive weather stripping, O-rings or a combination of the two. Make the grip from one solid piece or several sections, allowing chrome to show through. Secure O-rings in place with epoxy if you use them.

Add a few O-rings at the non-capped end of the pipe, spaced out slightly and held in place with epoxy (see Tips).

Add washers, bolts, switches, knobs, buttons or any other mechanical-looking controls to the sides of the pipe. Drill holes in the pipe to allow the pieces to lie flush against the smooth chrome surface. Secure all the parts in place with epoxy.


Step 4: At this point you are beginning to add interesting details; the specifics of what to use where is completely up to you.

Things You'll Need

  • Chrome sink drain pipe, 10 to 13 inches long, with one threaded end
  • PVC end cap, threaded, matching the size of the pipe
  • Black spray paint
  • Black foam weather stripping
  • O-Rings
  • Epoxy
  • Switches, dials, washers and bolts
  • Drill and metal bits
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About the Author

Alex Smith began writing in 2006 and brings a combination of education and humor to various websites. He holds a Master of Arts in theater and works as a professional makeup and special-effects artist.