Here is my version of the ROTJ Force Pike.
Materials:
1) Force Pike Body: 48" Wooden Pool Stick from Wally World
2) Force Pike Tip: Children Medicine Syringe
3) End of Force Pike Tip Nut: 9/16 Hex Nut from Lowes => Decided to eliminate this piece in final force pike
4) Rasp Base: 1/2 PVC coupling P/N 50105 from Lowes => Replaced with cut up glue stick
5) Rasp Teeth: Cut up ABS sheets => Used Rasp teeth pieces supplied from tb750
6) Force Pike Black Handles: 1 x Hoover Upright 16" Extension Wand Part # 38634078. Cut in two. My old vacuum had two extension wands, so I had a free spare.
7) Force Pike Black Handle Supports: Black O Rings of various sizes
8) Force Pike Pommel: 3/4" PVC Check Valve from Lowes
9) Force Pike Pommel Assembly Screw: Long Black Deck Screw from Lowes
10) Force Pike Paints: Grey Primer, Flat Black, and Silver from Lowes
Detailed Build:
1) Force Pike Body. I removed the little glued on plastic ring at the end of the 48" Wooden Pool Stick that I purchased. It gave a little edge for the Pommel to actually sit on. I sanded the pool stick down to get a smoother surface. A little trick after initial sanding is to spray it with the grey primer, which allowed me to see additional nicks in the wood that I first missed. There was actually a small gouge in the wood that I somehow missed. I filled in the nicks with wood putty, sanded smooth, and sprayed grey primer on the whole body.
2) Force Pike Tip: I used an old Childrens Medicine Syringe. I cut off the tip and filled it with wood putty. the pictures below show the unmodified syringe and a test fitting on the Force Pike Body before I cut off the extra piece at the base.
3) End of Force Pike Tip Nut. I found the perfect size hex nut to fit on my Force Pike. Removed and replaced with a simple rubber washer.
4) Rasp Base: Used part of a glue stick. I just cut the empty glue stick cylinder to the proper length to fit the resin Rasp teeth.
5) Rasp Teeth: Got 6 Resin Pieces from tb750 (Thanks John). Wrapped sand paper around the Rasp base and rubbed the resin rasp teeth pieces against it to get the proper curved shape to get them to sit flush with the Rasp base. I marked the Rasp base with a sharpie and glued the 6 Rasp teeth Here is an image of the unpainted ROTJ Force Pike rasp:
6) Force Pike Black Handles. I used an old Hoover vacuum extension wand. It was slightly tapered and could easily be cut with my dremel. I also used various black o rings to help support the handles (7: Force Pike Black Handle Supports). The handles are actually pretty snug without having to use any glue. Below are pics of the black handle before and after cutting it.
8) Force Pike Pommel. I didn't like using a faucet handle, so I found a PVC Check Valve with the general shape of the real Force Pike Pommel images. I had to cut off one of the ends with my dremel.
9) Force Pike Pommel Assembly Screw. I drilled a larger hole in the end of the pool stick and reused the rubber end that came with it. The rubber end can be seen in the above picture of the Pommel.
Here are test fitting images of the different components before actual painting.
Below pic is missing the Rasp Base.
Images after painting. I also smoothed out the area between the black handle with bondo before painting it for the final force pike.
Enjoy.
You've got some really good ideas there. I especially like the syringe as a pike tip. For some reason it's hard to find suitable parts that will work as a tip. I'm looking forward to seeing more photos as you approach completion.
