For the Darth Vader prop, I wanted to have a lightsaber attached to the hilt, but it would need to be extremely lightweight and cheaper than the $15 Walmart versions. Plus, it would need to be worth a minimal amount of time. Let’s complete this build in the time it takes to checkout at Walmart.
Starting with a cardboard tube from a roll of paper towels (or with a heavier section of PVC pipe), aluminum flashing tape is adhered in long strips the length of the tube. A cap for the bottom end is made out of craft foam, wrapped in the same aluminum tape, and hot glued on one end.
Black foam is used for the strip details on the handle, the switch and the front cover. Given that this item won’t be viewed up very close, hot glue and ACC (super glue) can be employed.
Additional details are fabricated from the tops of clear pushpins as well has a wire holder as well.
Instead of taking a small hobby knife to cut out various details, black electrical tape is used to mimic cut outs along the body of the lightsaber.
When you’ve assembled all of the materials, this project can be completed in about 30-40 minutes. Just make sure to have good reference material on hand and get creative with your material selection!