So when I built my saber a while back, one issue I came across was that when I tightened the hilt button down all the way (it’s a screw threaded button with spring) into the hilt, it would press the button on the chassis underneath all the way down without letting it up.
My ‘solution’ was to use a two-sided adhesive material under the bezel (it’s a QGJ hilt) to provide enough elevation that I could secure the button into the hilt by threading it in the bezel without it continuously pressing down the chassis button. It’s worked for a while, but lately I’m finding the button connectivity to be a little flaky in the other direction (letting the chassis button up even when I’m keeping the hilt button pushed down while swinging).
So now that I’m revisiting this issue, has anyone had a similar problem, and have a suggestion/solution?
Some pictures might be helpful.
Here’s a couple pictures, should show that I basically used a two-sided adhesive to serve as a cushion, which allows me to tighten the button down without permanently pressing down the button on the chassis (which is what happens by default if I just tighten the button down into the bezel/hilt. Not sure if others came across similar issues and what their solutions were
Yeh, I’ve had one or two of these in for repair with this issue. It was a while ago, but if memory serves, I had to 3D print a thin spacer to hold the bezel a little bit higher, as you’ve done with the soft pad. The trouble with a soft pad is just that - it’s soft, which makes the button action a little inconsistent. You really need something rigid. It might also be that the button plunger needs a little more travel, in which case you would need another spacer or washer on the threads of the silver plunger where it screws into the button. It would likely take a little bit of experimentaion and trial and error to find the right combination of spacer depths. Also make sure the chassis is secure n the hilt and not “floating” a bit as that too can give spurious button presses.
To be honest, most of what I use my 3D printer for is making tiny little components like this to fine tune how parts go together in hilts to make them feel nice and responsive.
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Thought I’d give an update 
- so my initial approach per above was to find some black washers with matching inner diameter/ outer diameter to replace the soft pad I had, but they were too thick to allow for the hilt button to thread in.
Finally I just opted to sand down the button on the inner chassis, to allow for the button to thread in with the bezel without any additional foreign objects, and that seems to have done the trick. Response is pretty good now too; the main issue was trying to trigger the clash lock and I seem to be hitting it on the mark now.
So yeah, cautiously optimistic now. I’ve considered this hilt done for a while now, but now it’s done done
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