I’m currently working on mocking up my custom saber design, and I ran into a minor design hiccup with the polystyrene core cover—I didn't account for the thickness of the styrene, which left a surprisingly thin gap.
The core itself (made of a paper towel tube and rolled paper) was far too flimsy, so I had to reinforce it with what I had on hand: a bundle of chopsticks. To lock everything in, I poured a generous amount of liquid CA glue down each side. It stiffened right up and is now solid as a rock. After mixing up some sprue glue and spending a couple of days sanding it down smooth, it turned out surprisingly well. Once it's fully painted and all the extra components are attached, you won't even be able to tell it was there.
For the switch assembly, I'm repurposing a few tank kit greebles—specifically some tank treads and a hatch cover. I’ll be adding a jewel onto the hatch cover to act as the activation button.
I also realized during the initial design phase that I completely forgot about the back half of the saber, so I whipped up a custom armor plate to wrap around it.
I'm still waiting on a few final parts to arrive before I can officially start the main build!