Since the first "Star Wars" movie came out in 1977, the lightsaber has been an iconic part of movie history. Lightsaber props can be made of plumbing parts, including using a chrome drain pipe as a base. If you prefer to use a PVC pipe for its durability, you must first make it look like chrome. After that, it is simply a matter of adding a grip and miscellaneous parts to make it look like a futuristic weapon.
Cut a piece of 1-inch PVC pipe to a length of 12 inches with a hacksaw. If desired, cut one end at a diagonal for a more visually interesting sabre.
Glue a PVC end cap onto the flat end of the pipe with PVC adhesive. Allow it to dry fully.
Lightly sand the entire pipe and cap with 400-grit sandpaper to prepare it for primer. Once this is done, sand it again with 600-grit sandpaper.
Wash the lightsaber with soapy water to remove any sanding dust and allow it to dry.
Spray the lightsaber with a thin coat of plastic primer and allow it to dry. Apply a second coat of primer and allow it to dry.
Sand and wash the lightsaber as detailed above to prepare it for paint.
Let the lightsaber sit for several days for the best adhesion of the primer.
Paint the lightsaber with several thin coats of chrome spray paint, allowing each to dry before adding the next.
Spray on two coats of Crystal Clear to protect the chrome finish.
Slip enough black O-rings onto the lightsaber to form a handle grip. Slide them all the way down to the cap, and then glue the top one in place with epoxy.
Glue additional O-rings, bolts, buttons, switches and other technological-looking components to the lightsaber to make it look like an electrical device. The layout and design is limited only by your imagination and the available parts.
If needed, drill holes in the lightsaber to allow parts such as bolts to lie flat.
Several thin coats of primer, paint or Crystal Clear are much less likely to produce drips than a single, thick coat.
Work in a well-ventilated area when spraying.