MetalMaster Chassis system 3.0 Manuel utilisateur

Metal Master chassis system 3.0

Instruction Manual

This is the manual for the Saber-chassis only.

It shows how to install the electronics and put together all chassis parts. This manual does not

show how to convert a Graflex Flashgun or setup a soundboard.

This manual contains the instructions for Metal Master chassis version

3.0

Metal Master ightsaber chassis is only recommended for experienced model builders

Manual Version 02.08.2022

Contents
Foreword  3
Tools 4
Additional parts overview 4
3D print parts overview 6
Emitter Section 7
Plasma Gate Section (Part 01) 8
Crystal Chamber Section (Part 02, Part 03 Part 04) 9
Main Section (Part 05, Part 06, Part 07) 10
Main Section (USB) 11
Speaker Section (Part 08) 12
C ecking t e printed parts 13
Preparing t e surface 15
Installation 18
1 Electronic wire 18
2 Speaker Chamber 19
3 Battery contact installation 23
4 Battery cover Part07 26
5 Charge PCB 27
6 Accent  ED/Pixel 31
7 Oled display installation 34
8 Fins installation (3D printed or laser cut) 36
9 Crystal chamber Part02 38
10 Installing t e Electronic parts 39
11 Plasma Gate 2.0 43
12 Spinning Plasma Gate (Part 01 SPG) 44
13 Blade  older – Emitter 53
14 Installing the top cover Part 06 58
15 Installing the Battery 59
2

1. Foreword

T ank you for c oosing my Graflex Lig tsaber C assis for your own Graflex based Lig tsaber

project.

The mb-sabers Graflex chassis design has been continuously developed and improved for over 3

years. MB-sabers focused on this one chassis design to create the best possible chassis for Graflex

based ightsaber.

A lot of experience and passion has gone into this design. And of course mb-sabers will continue to

work on improving this chassis and adapting it to customer needs in the future.

The Metal Master chassis design allows individual parts to be simply exchanged for the old version

after further development. This often allows a complete chassis to be updated without having to

re-buy all parts.

For creative design

The metal Master chassis gives a lot room for individual custom designs.

Use the basic chassis parts and add self designed parts and elements to it. Especially the crystal

chamber and the plasma gate can easily be modified.

For experienced obbyists

Editing and assembling the individual parts is not easy. 3D printed parts are not that accurate as

CNC machined parts. Adjustments always have to be made. A proper workspace and professional

tools are absolutely necessary. I only recommend building one of my chassis for experienced

hobbyists.

Responsibility

3D printed metal is conductive. The installation of all electronic parts must be done with care! MB-

Sabers cannot be held responsible for improper use or assembly of the Metal Master Saber

Chassis.

Print materials

The Metal Master chassis is specially developed for metal 3D printing. Most parts are available as

3D prints. These parts are designed for precious metal materials. These materials have the best

accuracy and usability. They can be drilled, cut and tapped very easy.

However, most parts are also available in steel or nylon plastic.

2. Tools
For assembling the printed chassis parts and installing the electronic parts you need different 
tools...
•sandpaper (240 grain and 600 grain)
•drill heads 1mm, 2mm, 3mm, 4mm
•small slot screwdriver
•double-sided adhesive tape (thin and foam)
•scalpel / small cutter
•tap M1.2 and M1.4
•glue (Pattex repair EXTREME and Epoxy)
•octite 648
•files with diamond grid (small and medium)
•soldering-iron and solder
•tweezers
•liquid rubber 
•insulating tape
•shrink tubing
•belt sanders small (for example Proxxon)
•power tool (Dremel or Proxxon)
3. Additional parts
Basic C assis parts
•3x M2 threaded steel rods  https://www.mb-sabers.com/shop
•1x M1.2 brass rod  https://www.mb-sabers.com/shop
•2x 40mm steel rods (1mm diameter) https://www.mb-sabers.com/shop
•4x 95mm steel rods (1mm diameter) https://www.mb-sabers.com/shop
•2x brass tubes 40mm x 4mm diameter https://www.mb-sabers.com/shop
•3x M1.2 countersunk screws https://www.mb-sabers.com/shop
•6x M2 nuts DIN934  https://www.mb-sabers.com/shop
•4x M1.2 nut https://www.mb-sabers.com/shop
•power switch (TS01CQE 3A 120V)DigiKey
•micro USB-B or USB-C port (female)  https://www.mb-sabers.com/shop
•1x AAA battery spring contacts  https://www.mb-sabers.com/shop
•1x AAA battery contacts  https://www.mb-sabers.com/shop
•3x M2 washer
•speaker cover ring  https://www.mb-sabers.com/shop
•speaker chamber accent  ED spacer  https://www.mb-sabers.com/shop
•Emitter blade holder https://www.mb-sabers.com/shop
4

Plasma Gate Parts
•3x screws 4-40 UNC 3/4” https://www.mb-sabers.com/shop
•3x M2 nuts https://www.mb-sabers.com/shop
•1x poly carbonate tube (10mm diameter) https://www.mb-sabers.com/shop
•3x steel tubes (3mm diameter) https://www.mb-sabers.com/shop
•3mm ultra bright  ED or pixel  ED https://www.mb-sabers.com/shop
Electronic parts 
•18650 3.7V  i-Ion Battery (protected only!)https://thesaberarmory.com/
Keeppower 3,7V 18650 Lit ium-Ion 3500 mA 
•1x 28mm speaker (max 12mm high) https://thesaberarmory.com/
•0.02 mm² (AWG 34) wire
•0.05 mm² (AWG 30) wire
•0.09 mm² (AWG 28) PTFE wire
•0.14 mm² (AWG 26) PTFE wire
•0.21 mm² (AWG 24) PTFE wire
•0.32 mm² (AWG 22) PTFE wire
•3mm accent  EDs
•SMD  EDs 0805
•single pixel  ED
•Soundboard https://thesaberarmory.com/
•USB charging PCB https://www.mb-sabers.com/shop
•Oled display 0,91” (128 x 32) 
•electric motor with gear box 1:136 (6mm) https://www.mb-sabers.com/shop
•NeoPixel connector (blade and hilt) https://thesaberarmory.com/
•High brightness  ED https://thesaberarmory.com/
•Blade parts https://thesaberarmory.com/
https://www.thecustomsabershop.com/
GRAFLEX parts
•GRAF EX flash gun https://thesaberarmory.com/
 https://graflexshop.com/
http://romanprops.com/
•GRAF EX add on parts https://www.thecustomsabershop.com/
https://thesaberarmory.com/
Blade older https://www.mb-sabers.com/shop
5

4. 3D print parts overview

Part Variations

Some parts have variations!

Depending on technical aspects like:

Blade style: NeoPixel or High Brightness ED

Plasma Gate: Standard or spinning

Oled display: YES or NO

USB: USB-B or USB-C

Or design aspects:

Crystal C amber: number of Fins

Main Section: number of accent ED on Part06

Print Materials

3D printed precious Metal:

The metal parts are designed for precious metal material printing (Silver, Brass, Bronze).

These materials have the best accuracy and usability. They can be drilled, cut and tapped very easy.

However, most metal parts are also available in steel or nylon plastic.

3D printed Steel:

Steel material prints are not recommended for inexperienced obbyist. But it is absolutely

possible to work with printed steel parts. It takes some time to prepare the parts to make them fit.

The standard SW steel material is brittle and cannot be drilled, cut or tapped! All steel material

prints have an accuracy of +/- 5%!

Anyway, the lower cost of steel prints are of course a good way to safe money.

Emitter Section
Variation A (short) t in back plate
for Neo Pixel
Variation B (long) t ick back plate
for  ig  brig tness LED
Parts Parts
Emitter glass-eye adapter Emitter glass-eye adapter
Emitter add-on A s ort Emitter add-on A long
Emitter add-on B Emitter add-on B
Emitter add-on C s ort Emitter add-on C long
Emitter add-on D s ort Emitter add-on D long
Emitter add-on E Emitter add-on E
Emitter 2.0 NeoPixel Connector  older 
7

Plasma Gate Section (Part 01)
Standard Plasma Gate Spinning Plasma Gate (SPG)
precious metal or steel precious metal steel
parts parts parts
Part 01 Plasma Gate 2.0 A Part 01 SPG front cast metal Part 01 SPG front steel 
Part 01 plasma gate 2.0 B Part 01 SPG back cast metal Part 01 SPG back steel 
Part 01 Plasma Gate 2.0 C Part 01 SPG tube  older 
Part 01 SPG ring 
Part 01 SPG spacer Part 01 SPG spacer 
Part 01 SPG magnet Part 01 SPG magnet 
Part 01 SPG details Part 01 SPG details 
Part 01 SPG motor  older Part 01 SPG motor  older 
8

Crystal Chamber Section (Part 02, Part 03 Part 04)
Crystal Chamber with
5 fins
Crystal Chamber with
6 fins
Parts Parts
Part 02 A Part 02 A 
Part 02 B Part 02 B 
Part 02 C (crystal  older) Part 02 C (crystal  older) 
Part 02 D (led  older) Part 02 D (led  older) 
Part 03 Part 03 
Part 04 (5 fins) Part 04 (6 fins) 
Pipes Add On Pipes Add On 
9

Main Section (Part 05, Part 06, Part 07)
V1 V2 Oled
Parts Parts Parts
Metal Master 3.0 part 05 Metal Master 3.0 part 05 Metal Master 3.0 part 05 
Metal Master 2.0/3.0 Crystal
 older 
Metal Master 2.0/3.0 Crystal
 older 
Metal Master 2.0/3.0 Crystal
 older 
Metal Master 3.0 part05 slider Metal Master 3.0 part05 slider Metal Master 3.0 part05 slider 
Metal Master 3.0 plate and
spacer 
Metal Master 3.0 plate and
spacer 
Metal Master 3.0 plate and
spacer 
Metal Master 2.0/3.0
Insulation 
Metal Master 2.0/3.0
Insulation 
Metal Master 2.0/3.0
Insulation 
Metal Master 07 Metal Master 07 Metal Master 07 
Metal Master Battery cover Metal Master Battery cover Metal Master Battery cover 
Metal Master 3.0 part06 V1 Metal Master 3.0 part06 V2 Metal Master 3.0 part06 Oled 
Metal Master six-pack smd
LED Holder 
Metal Master double smd LED
 older 
Metal Master LED Holder Oled 
Metal Master Oled cover SET 
10