So, I’ve been on a Star Wars kick lately with the new movie due out soon.  What better way to celebrate than to make a mini flashlightsaber with a flashlight from Harbor Freight and some 3D printing?

Your cast of characters:

  • Mini flashlight from Harbor Freight – you can get two of them for $2!
  • 3D printed hilt and blade parts from this awesome build on Thingiverse
  • Glue – my first attempt used superglue.  It was OK, but messy and left an unsightly film on the metal parts of the flashlight.  Second time around, I used hot glue, and it was perfect!
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Harbor Freight Flashlight

 

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3D printed hilt and blade parts. I printed the blade in translucent PLA, but it will also work with non-translucent.

 

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Remove the wrist strap from the flashlight.

 

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Heat up your glue gun!

 

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Glue the flared hilt piece to the top of the flashlight.

 

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Glue the non-flared piece to the bottom, over the power button.

 

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Your hilt is just about ready! You can glue the button on at this point as well. I secured mine over the Harbor Freight logo.

 

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Almost done! Now glue the blade inside the flared hilt piece over the bulbs.

 

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Light it up, baby!

May the Force be with you…

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