I started working on a 'functioning' lightsaber - with sound and reactions on clashing and spinning about and such. I used blender to figure out spacing and mounting for all the components, as well as make some models to 3DPrint and vectors to cut. This is the end result.
All the hardware is shaped and sized based on the real-life product in use. The end result will be a chassis of cut-acrylic held together by four #4-40 thread poles that slips into a 1-1/4" sched40 PVC pipe, which will then be dressed and decorated.
For the real project, I'm currently waiting on the last piece to come in, which is of course the kingpin to getting it all started: the #4-40 thread rods! Once those arrive I can start assembling the saber.