Darth Dog's ROTJ Royal Guard WIP

[Darth Dog]

To make the rasp i used a worm gear that was left over from a garage door repair.


I used 3mm pin stripe tape to mark off the 8 row of teeth.


I then used a dremel with a cutting disk to cut a line down the screws. Then I placed the cutting wheel into the cut and then leaned it to the left and then right to remove the material not covered by the tape and produce the angle of the teeth.


I then used a small file to clean up the teeth. I sprayed it with Rustoleum gold paint and slid it onto the ski pole. I probably spent about 20 minutes converting the part.

[Darth Dog]

Wasn't happy with the tip as I originally had it.


Looking at some pictures of the original I decided to make mine look more like the worm hob that was used. I bought some 1/2" brass tubing from the local hobby shop. I used part of the worm screw that was cut off when I made the rasp as the spacer on the brass tube. I then cut the tip off an old tube of grease for the silver pike tip. I used epoxy putty for the joint between the brass tube and the spacer and also to fill the end of the tip.


If I were to do it again I would make the brass tube about 1/2" shorter and make the epoxy joint smaller. Otherwise I'm pretty happy with the outcome. I have another ski pole, rasp, faucet handle, shrink tube, and brass tubing so I can make another in the future.

[Darth Dog]

Should be placing order with FP in a few days for soft parts. Hope to be coming up on the helmet list in the next week or so. Shooting for a mid June approval.

[V-cell]

Beautiful work on the force pike DarthDog. We will be waiting for future updates and we will celebrate when you join our family!

[Darth Dog]

Thanks much V-Cell.

[Gruff]

Nicely done

[Darth Dog]

Thanks Gruff.

[Darth Dog]

Have placed order for FP soft set and waiting to hear word on helmet. Nothing to do so I decided to make another pike. Want this one to be a little better. The first pic shows my first pike and the ski pole for the second.


Using a razor knife I removed the handle and the lower base from the ski pole.


This time I wanted to see if I could polish the aluminum pole. After striping the paint off with 140 gr sand paper I polished it using 400, 800, 1000 and then 2000 gr sand paper. I finished it off with polishing compound and now have a nice shiny pole.

[Darth Dog]

I started work on the already taped off worm screw from the garage door opener. I used a dremel with a cutting wheel to cut a line down the middle and then remove the remaining material at an angle to produce the teeth of the rasp. In the first pic you can see the teeth making process has began.


The teeth are now formed and have been cleaned up with a file. Next I will cut the ends off.


In the next pic you can see the ends have been cut off. The narrower of the 2 will be used as an end piece later. The grey 'insert, female adapter 1/2' has had the larger end sanded down some so that it will fit into the end of the 'backflow prevention valve' which has also had the threads on the female end sanded down to also aid in the fitting.


Next is the brass tube that will extend off the rasp. I cut it to be 1 1/3 the length of the rasp as it appeared to be in the reference photos. The end piece removed from the rasp has been glued on the tube and epoxy putty has been applied as per the photo of the worm hob. It will be the end of the week before I can do any more work on this.

[JesterTDA]

Does the worm gear slide on or did you/do you need to cut it in half and fill it? I need to pick up a gear myself and find out as I use a ski pole also.