Here where all of the pieces after being painted for a first layer. I found a white-pearl-metallic paint that replicated what I was seeing in the picture of the prop, and I was quite pleased. What sucked was that in the end every piece needed MANY coats of this stuff to get them properly coated and matching each other.
Here is the entire lot of 'stuff' that it took to make the katana. You can see the battery pack (now with longer wires to make it up through the hilt), the rods that go along the outside, and some internal pieces that blocked the original saber from going up or down further than it should.
Here was the hilt being put together - just after all of the electronics were, with incredible difficultly, managed to be put in the small part of the hilt between the bottom of the lower metal cup and the thinnest part in the middle of the hilt. It wasn't easy. It just BARELY fits. Very, very barely.
As always - I give a wrap up. Honestly? I'm super pleased with this prop. The only small faults I have are that it isn't smooth everywhere as metal should be but considering this is all hand cut, somehow managed together, and painted up as it never should have been? I think it turned out very well. It can be waved around quite successfully even though it looks very delicate. I mean it isn't going to survive hitting someone, but it can survive a con I'm fairly sure.
The client - who lives close enough to have watched it all come together - is incredibly happy with it. I'll be posting a shot of her with the katana soon - in fact I have two other clients who were kind enough to send me shots of them and their props while they were in full costume! I'll do a little non-tutorial post for them.