Buy the chrome nipple pipe, chrome bushing, rubber padding and chrome reducer coupling at the same time to make sure they have the right sizes when fit together. Once you have these materials, bring the chrome pipe when buying your small LED flashlight to ensure you get the right fit as well. Gather these materials, along with the necessary tools, for the construction and assembly of your lightsaber prop.
Fit the flashlight into the chrome pipe, then mark where the flashlight's on-off switch should be located.
Drill a hole on the mark on your chrome pipe. Make sure it is large enough to accommodate the on-off switch of your flashlight.
Insert the flashlight into the chrome pipe. Ensure it fits snugly and that the on-off switch matches the drilled hole on the pipe. Secure the inserted flashlight by covering the top of the pipe with adhesive tape, which can be packing or duct tape.
Screw the chrome cap onto the lower end of the chrome pipe, then glue a neoprene pad onto your cap.
Screw the bushing on top of the chrome cap, just over the adhesive tape area. Follow this with the screwing of the reducer coupling onto your bushing as well.
Cut a long piece of acetate for your plastic tube, which serves as the lightsaber's blade. The acetate will provide color to your lightsaber. In terms of size, it depends on how long you want your lightsaber blade to be, which is also primarily based on the length of the plastic tube you will use. As a guide, cut a 36-inch by 6.5-inch piece of acetate for a plastic tube of the same length.
Roll and insert the acetate into the plastic tube, then glue this tube onto the reducer coupling. Allow the glue attachment to set by keeping your hands securely holding the tube on your reducer coupling.
Turn on the flashlight to start using your do-it-yourself lightsaber.