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Here is a diagram of the catch replica's parts. This was made with styrene tubing, and chrome ball/post earings. I'm not sure of the exact sizes, I just eyeballed it. I'll see about getting some exact measurements. The round tubes have to be able to fit inside one another, and then inside the square tube. The earing should just fit inside the larger round tube. First, cut the square tube like the red lines show, leaving the bottom so the two halves are still joined. Next, cut 2 separate sections the same size as the 2 square boxes. Epoxy the round sections into the square ones, and make sure to let the epoxy run into the triangular gaps between the round tube and the squares. Don't be afraid to be messy with this part, you want it to look like a solid square that has a hole running through it, so if you plug the round tube slightly, you can always drill it out again later. You'll most likely have to do some fine sanding to shape this just right. After you've finished the main part, cut 2 sections of the smaller tube, just slightly shorter than the boxes. The earing and post will be glued into this. The boxes can now be epoxied to a rectangular strip (leftover from the hitch cover) with holes in either end. This will be the plate that gets mounted to the saber. The holes should be placed right after the ends of the boxes. Once drilled, round off the strip around the hole. Once you've glued the boxes to the mounting plate, paint it black. Now slide the earing assembly into the boxes. The earings should stick out only halfway out the other end. If you cut the smaller tube right, you should have enough room to place a short round section of solid styrene rod into the end, notched to look like the head of a screw. |