DISASSEMBLY AND ASSEMBLY DOCUMENTATION PAGE
USING AN ACTUAL GRAFLEX FLASH HOUSING
TO CONSTRUCT AN "ANH" LIGHT SABER
This page shows my disassembly of a REAL Graflex flash housing in order to add a LED Luxeon conversion kit.
Again, I ordered a Luxeon conversion kit from the kind folks at The Graflex Shop. They have been very helpful with great communication, I highly recommend dealing with them!
I currently have two REAL Graflex flash housings (called a "hilt") to start the conversion process.
These Graflex flash housings were the actual type units used in the original film (episode IV or A New Hope (ANH)).
To make just a STATIC prop, all you have to to is to add:
1) 7 "T-track" grips to the bottom tube. This is the saber's grips. Again, some say rubber was used in the originals and some say plastic "T-Track" from furniture was used. I have both now, thanks to the RPF members! Thanks D.W. Marcum for the plastic ones.
2) Add the correct 7 bubble "calculator" strip to the flash clamp.
3) Drill a hole and add the "D" ring to the bottom housing
Since this unit is getting a Luxeon LED, removable blade, etc. it's getting the full disassembly treatment...
08/17/07 : (Step1) Remove the 4 each side pins using the pin tool if got from GraflexShop.com.
Also removed the bottom retaining screw from the flash bulb socket to housing.
Blue tape is to keep the top red button from swinging around and scratching the housing.
08/17/07 : (Step 2) I removed 2 each top pins then the "L" shaped top battery contact came out.
For some reason these contact pins do not have the same pattern as the side ones. I used a pair of needle nose pliers to carefully loosen them then removed the pins, then the original top battery contact.
08/17/07 : (Step 3) Now for the fun part. The pin that hold the front flash socket is crimped on the rear end.
This picture of course is from the front end, you can see it's just starting to move out.
I used a couple of punches from my gun smithing kit and carefully drove the original pin out and removed the flash socket.
I also sprayed some lube (Break Free CLP) on the pin assembly to cut down on any friction while driving out the retaining pin.
08/17/07 : (Step 4) Pin has been successfully driven out without any damage to the Graflex housing.
BTW: The Graflex is a brass housing that is chrome plated, so you have to be careful! The vertical brackets can be easily over stressed/bent when trying to remove the original pin...
Again, tape is to keep from scratching the Graflex finish.
08/17/07 : (Step 4) Graflex Flash Socket finally removed. Again, the Break Free CLP lubricant made it easier to get the original Flash Socket out of the housing. There is a small broken black tab laying there. Found where it goes.
Not sure why it broke, I just tapped the Flash Housing from the rear with a wooden dowel to force the Flash Socket out of the housing.
08/20/07 : I'm keeping the original side slide switch, but I had to cut it :( in order for the GS Blade Adapter Kit to fit inside the front Graflex housing. Here is before and after cutting the slide switch tab:
08/20/07 : Slide switch tab cut with Dremel and cut-off disk.. :(
08/20/07 : Will continue to update this page as progress is made...
Last updated: September 03, 2007
Time: 1259 EST