I am a huge Star Wars fan! I also follow the ways of the jedi. In doing so, I have, like so many others out there, constructed my own light sabre. I had a piece of aluminum machined by a local machine shop. I added the switchbox, the emitter covering, a few thumbknobs for blade adjustments and recharging, and of course, the "D" hook to attach it to a utility belt. I'm not totally sure that it is complete, I may add some other stuff to it, or re-do the switchbox placement.
My next big projects are to create a Jedi costume and a full Stormtrooper suit from fiberglass. It's gonna take some time, but I really want to see what I can do. I've gotten a lot of good info from some pages here on the net.
Enjoy!!