Friday, June 20, 2014

Obi-Wan Kenobi Light Saber Mod into an E-cig



Recently helped a friend modify an Obi Wan Kenobi .45 scale light saber into an e-cig.  The model is similar to the one in this Ebay listing, and is getting pretty rare.  They got the idea from a forum post that did a much less elegant job, but contains a slightly bigger battery.  Here are brutal steps for our build:
  1. Get the model disassembled.  You should end up with:
    • An end cap
    • Chromed plastic 6 spoke pommel cap
    • A die cast metal shroud
    • Plastic insert for metal shroud
    • Belt loop with screw
    • Red and brass buttons with screw
    • Die cast fore end
    • Plastic insert for metal fore end
    • 3x chromed plastic pins that hold the plastic insert inside the metal fore end
  2. Find a battery.  We were able to fit a 180mAh long cylindrical 3/8" diameter one into the case.  It had a button on one end that fit just right so the fitting just comes to the fore end and a hole can be opened in the plastic insert for the metal fore end to allow access.
  3. Vice the metal fore end by the wider cap (and not the base) into no-mar jaws and drill out the central hole with a 3/8" bit.  I would suggest a drill press for this operation, though a hand drill will do in a pinch.  A Dremel did not work for this due to hole size.  The metal is aluminium, so it shouldn't be too rough to do on most metal bits if you go slow and break your chips.  NOTE: we busted the spindly base off the wider fore end and snapped the 3  connecting bars by holding the fore end in the vice by the body of the fore end and not the cap.  They went back on with superglue after we matched up the shear patterns, but avoid this if at all possible.
  4. Gently vice the plastic insert to the fore end and drill it out to 3/8" as well.  While you have it disassembled, drill the hole for your the button on your battery as well.  NOTE: be careful not to deform the plastic insert in the vice.
  5. To reduce rattle inside the case, wrap some electrical tape around the parts of the battery that don't precisely fit (and are hidden in plastic).
  6. Attach a wooden or metal extension on the battery cap and drill it so the belt loop screw can be reinserted.  We used wooden dowel screwed onto the plastic cap at the end of the battery, then epoxied in place. The belt loop screw holds the metal shroud and plastic fitting to the battery in the same manner as the fitting and battery button hold the fore end tight to the battery.
  7. Attach your fitting and vape!
Fully Assembled

Coil Removed

Side View with all Vape connectors removed



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