Place the 6-inch chrome-plated slip joint into the vice grip. Cut the threads off the pipe using the cutting attachment on the rotary tool.
Cut the ends of the slip joint so the total length of the slip joint is 3 1/4 inches. Use a measuring tape to check the length.
Draw a straight line on a piece of paper, measuring 1 1/8 inches in length. Draw two lines (parallel to one another), one from each end of the line, to form two right angles --- each line measures 1 7/16 inches in length. Place a measuring tape in the middle of the first line drawn, parallel to the two other lines, and measure 1 7/8 inches --- put a small dot. Connect the dot to the ends of the two parallel lines. The shape formed is similar to a shield. Repeat this process on another piece of paper. Cut out both shapes using scissors. Tape them to the side of the 3 1/4-inch slip joint, on opposite sides, with the points of the "shields" pointing in the same direction --- toward a cut end of the slip joint.
Cut out the shapes of the slip joint with the cutting blade on the rotary tool. Clean the edges with the buffer attachment for the rotary tool.
Place the 12-inch-long, 1 1/4-inch-diameter slip joint into the vice. Cut off the threads using the disc-shaped cutting attachment on the rotary tool. Cut off the opposite end of the slip joint, making the total length of the slip joint 6 inches. Place the 12-inch-long, 1 1/2-inch-diameter slip joint into the vice. Grind off the threads using the grinder attachment on the rotary tool. Do not grind the edge of the slip joint --- leave a small edge. This is important and will be needed later during assembly. Cut the opposite end, making the slip joint 11 1/8 inches long.
Draw a straight line on a piece of paper, measuring 2 3/8 inches in length. Place the measuring tape in the middle of the line and, making a right angle with the measuring tape, measure a total distance of 3 7/8 inches. Draw a small dot. Consider the dot the tip of a bullet and draw a bullet shape, connecting the dot to the two edges of the line. The finished shape resembles a bullet. Cut out the shape using scissors. Tape the shape to the 6-inch slip joint with the tip of the bullet pointing toward one of the cut ends. Cut out the shape on the slip joint with the cutting blade for the rotary tool. Clean the edges with the buffer attachment for the rotary tool.
Cut pieces of the vinyl rubber to fit inside of the 3 1/4- and 6-inch slip joints. Slide the vinyl rubber inside of each slip joint, using glue to hold the vinyl rubber in place.
Apply a thin layer of petroleum jelly to the 11 1/8-inch slip joint. Slide the 3 1/4-inch slip joint onto the 11 1/8-inch slip joint with the point of the "shield" facing away from the lipped edge. Rest the edge of the 3 1/4-inch slip joint against the lipped edge of the 11 1/8-inch slip joint (if the lipped edge was ground away earlier, the pieces would not hold together --- this is why it was important to have the lip). Slip a rubber O-ring onto the slip joint, pushing it to the edge of the 3 1/4-inch slip joint. Slip a second rubber O-ring onto the slip joint, pushing it down until is 1 inch away from the first O-ring.
Slip the nylon slip joint onto the chrome slip joint, pressing it against the second O-ring. Slide the 6-inch chrome slip joint onto the 11 1/8-inch slip joint with the tip of the "bullet" facing away from the lipped edge. Slip the rubber slip joint onto the end of the 11 1/8-inch slip joint to complete the handle of the lightsaber.
Cut the wooden dowel to the length of your choice. Pick a length that will look and feel right when holding the lightsaber, somewhere around 2 1/2 to 3 feet in length. The wooden dowel acts as the lightsaber or, if you are using computer graphic technology, it will act as the reference point during editing.
Paint the dowel your preferred lightsaber color. Some examples of popular "Star Wars" characters and their lightsaber color are red (Darth Maul, Darth Vader), green (Yoda, Luke Skywalker) and blue (Mace Windu, Obi-Wan Kenobi). If you are using computer graphics to create the lightsaber effect in your movie, painting the dowel is not necessary, but it does make a more visible visual aid.
Slide the wooden dowel into the open end of the lightsaber handle, securing it with glue.