Fett263's "Exar-Kun" Dual Blade Staff, Single Proffieboard Saber

Starting a new build. I picked up a Korbanth “Corruption” Exar-Kun hilt and will be installing it with a single Proffieboard to both test and utilize OS7’s new “Secondary” Blade capabilities (seen here: ProffieOS7.x "Secondary Blade Effects for Staff/Dual Blade Saber" pre-alpha discussion)

I wanted to give a shout out to Dan at Korbanth, he created a modified chassis to assist in the project, as the normal set up would be for 2 boards. He worked on modifying the existing chassis design so the wires can pass the speakers to allow for one board to control both ends.

I’m just waiting on the last parts to come in and I’ll be slowly assembling and documenting here.

The plan going in will be to have two batteries and two speakers running on a single Proffieboard set up with the OS7 secondary and conditional effects to allow individual control of the two blades from the solo board.

This saber has a single middle section and two ends that screw in from the side.

I will be using a 10-pole connector on one side (right in pic) to connect the neopixel connector, battery, button and switch.

Since the 10-pole connector is indexed and the two end chassis are also “fixed” for the button plungers, the current plan is to just hardwire the left chassis and center with enough slack to allow the center chassis to spin when the right side is connected.

For ease of access I will be putting the board in the left chassis and the center chassis will just house the speakers and 10-pole connection. This way I can unscrew the ends to access the two batteries or board and would rarely need to get to the center chassis.

One thing I haven’t decided yet is whether to wire the buttons as dual POWER or POWER and AUX. The placement of the buttons is fine if you have two boards, but if you’re using one board and holding the hilt with one hand you can’t really access both buttons. So the initial plan is to run this as a 1 button saber with both buttons wired as POWER so it doesn’t matter which side is pointing up. Of course, those of you who know me, also know I don’t much like 1 button set ups, so I may change course as I start working but that’s the initial plan.

I’ll continue to update this thread as I work on it, so check back for updates.

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I like the work mat. Got a link for it?

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They have a few sizes in their Etsy store, this was the one I got. They have a few color options as well.

The mats are really sweet. About to pick up a second one.

@Fett263 I’m down to see this build-out for sure, you know I liked the dual control demo.

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Great, now I had to go buy that hilt. Thanks lol

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Nice! I’m holding off on saber expenses for a bit so post your build also.

Some progress. I’m starting with the right chassis which will connect to the others via the 10 pole connector.

Added a small brass rod to act as the index for the connector:

Wired up the connector:

And FINALLY got the wires routed after having to come back at it several times. Definitely a tight fit through the opening under the battery holder. Note to self, route the wires first next time, probably save some headaches.

I will need to wire the button and feed the wires separately and then splice to the connector wires as the tiny path for the button wires is too far inside to get at even with tiny tweezers.

Will try to get some time later in the week to finish up this chassis.

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Is the brass rod intended to be a conductor or just something to act as a peg for fitment?

Just a peg for alignment.