MetalMaster Chassis system 3.0 Instruction Manual

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Download this 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 Lightsaber chassis is only recommended for experienced model builders

Manual Version 02.08.2022

Table of Contents

Need help?

Do you have a question about the Chassis system 3.0 and is the answer not in the manual?

Questions and answers

Summary of Contents for MetalMaster Chassis system 3.0

Page 1 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 Metal Master Lightsaber chassis is only recommended for experienced model builders Manual Version 02.08.2022...
Page 2: Table Of Contents
Contents 1. Foreword 2. Tools 3. Additional parts overview 4. 3D print parts overview Emitter Section Plasma Gate Section (Part 01) Crystal Chamber Section (Part 02, Part 03 Part 04) Main Section (Part 05, Part 06, Part 07) Main Section (USB) Speaker Section (Part 08) 5.
Page 3: Foreword
Foreword Thank you for choosing my Graflex Lightsaber Chassis for your own Graflex based Lightsaber 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 Lightsaber.
Page 4: Tools
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) •...
Page 5 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 LED or pixel LED https://www.mb-sabers.com/shop Electronic parts •...
Page 6: D Print Parts Overview
3D print parts overview Part Variations Some parts have variations! Depending on technical aspects like: Blade style: NeoPixel or High Brightness LED Plasma Gate: Standard or spinning Oled display: YES or NO USB: USB-B or USB-C Or design aspects: Crystal Chamber: number of Fins Main Section: number of accent LED on Part06...
Page 7: Emitter Section
Emitter Section Variation (short) thin back plate Variation (long) thick back plate for Neo Pixel for high brightness LED Parts Parts Emitter glass-eye adapter Emitter glass-eye adapter Emitter add-on A short Emitter add-on A long Emitter add-on B Emitter add-on B Emitter add-on C short Emitter add-on C long Emitter add-on D short...
Page 8: Plasma Gate Section (Part 01)
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...
Page 9: Crystal Chamber Section (Part 02, Part 03 Part 04)
Crystal Chamber Section (Part 02, Part 03 Part 04) Crystal Chamber with Crystal Chamber with 5 fins 6 fins Parts Parts Part 02 A Part 02 A Part 02 B Part 02 B Part 02 C (crystal holder) Part 02 C (crystal holder) Part 02 D (led holder) Part 02 D (led holder) Part 03...
Page 10: Main Section (Part 05, Part 06, Part 07)
Main Section (Part 05, Part 06, Part 07) 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 Metal Master 2.0/3.0 Crystal Metal Master 2.0/3.0 Crystal holder holder holder Metal Master 3.0 part05 slider Metal Master 3.0 part05 slider Metal Master 3.0 part05 slider...
Page 11: Main Section (Usb)
Main Section (USB) USB-B USB-C Metal Master 06 Tech USB-B Metal Master 06 Tech USB-C...
Page 12: Speaker Section (Part 08)
Speaker Section (Part 08) Metal Master Speaker Chamber Metal Master 08 (speaker cover)
Page 13: Checking The Printed Parts
Check the metal printed parts (especially standard steel) After the printed parts arrive, they must first be inspected. Most materials do not pose a major problem. However, parts printed from standard steel materials may have imperfections. Nylon or precious metal parts shouldn't cause any problems. Check all parts for: - closed / blocked holes (try to push rods through each hole) If there is a blocked hole make a picture (for Shapeways) before you do anything else.
Page 14 - damaged surface caused by removing sprue marks. During the printing process sprues are added to the geometry. These sprues will be removed after the printing process. Sometimes Shapeways damages the part. Please contact Shapeways and reclaim the bad print. Send them the picture of the issue. They will reprint this part! Use this text: I know the production process.
Page 15: Preparing The Surface
Preparing the surface 3D printed metal parts are never perfect! They all need post processing to make them fit and look good. Depending on the material, the parts require more or less work. Precious metals require the least amount of work. Standard steel needs the most amount of work. Tools - power tool and grinding heads - diamond files (small)
Page 16 Steel parts in general: Steel parts do not fit without sanding. Each part has to be sanded. Take your time. For steel parts use your Dremel or Proxxon power tool with a grinding head. For the finish use a belt sander (80 grit and 180 grit). There are several areas which have to be sanded to make sure all parts fit together.
Page 17 Soundboard cover Metal Master 06 (steel) Some areas of the soundboard cover Metal Master 06 need special attention. The area around the “light holes” inside the cover need to be sanded carefully to make sure the LED holder fits. This area has to be nice and smooth.
Page 18: Installation
Installation Safety first ! Please remember that metal materials are conductive! You have to make sure that the battery contacts are well insulated as well as all other electronic parts. Do not mix up the electronic poles. Install the contacts like shown on the pictures. Electronic wire Use PTFE wire.
Page 19: Speaker Chamber
Speaker chamber M2 threaded rods preparation Install one M2 nut on each M2 threaded rod end (2x). You need two 135mm long M2 rods. The third one is shorter and will be installed later! Use Loctite 648 to glue them in position. Let it dry over night. These three rods have to be installed before the speaker chamber is screwed on...
Page 20 Preparing the speaker chamber LED-SPACER The spacer guides the speaker chamber's accent LED light. Remove the blue foil from the LED spacer. This part does not have to be glued. Just place it between part 05 and the speaker chamber. Attach a thin self-adhesive mirror film to the side facing the chamber.
Page 21 Assembling the speaker chamber 1. Install the two M2 rods into Part05 first! 2. Add the four prepared 1.2 mm rods to Part05 3. Add the LED spacer and the chamber to Part05 and mount it with three M1.2 screws 4.
Page 22 Preparing plate and spacer (main plate, board holder, switch holder) 1. Separate all three parts and sand down the grainy surface. 2. Install the main plate into Part05. NO glue needed! 3. Add the power switch TS01CQE and the slider to the switch holder 4.
Page 23 Preparing the power switch slider Install the slider (together with the power switch and the switch holder) into Part05. Attach Part06 to Part05. Check how the slider knob fits into the cut out of Part06. Adapt the knob by sanding the two red marked faces till it fits into the cut out perfectly.
Page 24 Preparing nylon insulation parts Separate all three nylon insulation parts and sand down the grainy surface. The insulation parts for the positive pole contact needs special attention! First sand down the red marked face of the bottom part till it lines up with the contact plate surface! Then sand down the red marked face of the top part.
Page 25: Battery Contact Installation
Battery-contacts installation Important: The battery-contacts will be installed after the main plate! The spring-contact just has to be pushed into the slot. No glue needed! The flat-contact must be inserted at an angle of 40°. Then push it down to the final position.
Page 26: Battery Cover Part07
Battery cover part07 Battery cover adjustments Metal Master 08 has got four spacers to make sure the cover has a nice fit. Steel material has +/- 5% tolerance in any dimension. The four spacers must be adjusted in length. Battery cover add-on installation - Add two stripes of double-sided adhesive foam tape as shown in the picture in red.
Page 27: Charge Pcb
Charge PCB Preparing the Charge board PCB 1. Remove the USB port 2. Solder a 4cm AWG 28 wire to the B- pad 3. If you like to have the two indicator LEDs on a different position, remove them. External charging indicator LED position You can add charging indicator LEDs to the chassis cover Part06.
Page 28 Preparing the SMD charge LED You need a 0605 Bi-color SMD LED (usually green/red). Add 5cm AWG 34 wires to the four solder pads. Depending on where the LED will be placed, glue it into the Part 06 LED holder or not. Wiring the indicator LED to the charge PCB Solder the four AWG 34 LED wires to the pads on the charge-PCB as shown on the picture.
Page 29 Wiring the USB-C port The AWG 34 wires should be twisted. For the USB-C port the wire bridge should be at least 4cm long. Add liquid rubber to the solder joints for protection. Wiring the USB-B port The AWG 34 wires should be twisted. For the USB-B port the wire bridge should be at least 3cm long.
Page 30 Attaching the USB port to the chassis Part06 tech Solder the AWG 28 wires to the charge PCB (IN-/IN+). Wire length: USB-B: red 4.5cm / black 3.5cm USB-C: red 5.5cm / black 4.5cm Install the USB port into Part06 TECH. Make it fit first. Maybe some sanding is needed. Then place it into the slot.
Page 31: Accent Led/Pixel
Accent LED/Pixel Preparing 5050 RGB Pixel LED Because there is not much space for accent LED/Pixel, single pixel without PCB have to be used. In this case a common LED SMD 5050 RGB WS2812B is used. Solder the wires as shown in the picture Din: AWG 30 VCC:...
Page 32 Speaker chamber accent LED installation The speaker chamber has got a slot for one 1206 smd LED. Glue the smd LED into this slot directly onto the spacer. Cover the LED-back with black liquid rubber. Lead the wires to and through the through hole. Top cover (Part 06) accent LED installation Most Part06 LED holder are designed for 0805 SMD LEDs.
Page 33 There are different smd LED holder available... The six-pack is designed for the top cover with six light holes V1. All other smd LED holder can be used with all Metal Master top covers. One version is for one 3mm LED.
Page 34: Oled Display Installation
Oled display The top cover Metal Master 06 Oled is designed to integrate an standard Oled display with 128x32 pixel resolution. Oled display modifications Before the Oled display can be installed into the chassis cover, it has to be modified. Otherwise it would not fit.
Page 35 Oled display installation 1. Solder AWG 34 wires to the four pads in PCB direction. 2. Insulate the solder pads with liquid rubber and adhesive film. 3. Apply thin double sided adhesive film to the top end of the Oled window as marked in the picture in red. 4.
Page 36: Fins Installation (3D Printed Or Laser Cut)
Fins installation (3D printed or laser cut) Fin variations It is possible to use either 3D printed Part04 fins or laser cut fins (from www.mb-sabers.com) with M2 spacer. It doesn't matter what kind of spacer are used or how many fins. Important is only to keep the chamber length equal or smaller than 31mm.
Page 37 Preparing the U-rods The U-rods for the fins are a design element, which can also be modified. You need at least two 70mm rods with 1mm diameter. - Bend them with round nose pliers to the U-shape you can see on the pictures. The distance between both ends is 5.5mm.
Page 38: Crystal Chamber Part02
Crystal chamber Part02 1. Stick two brass tubes (35mm long / 4mm diameter) into the two holes from Part02A. 2. Slide the 3D printed tubes- add-on loose over the tubes. Don´t glue it on. 3. Install the crystal 4. Place Part02 with installed brass tubes over the three threaded main threaded rods 5.
Page 39: Installing The Electronic Parts
Installing the Electronic parts Now it´s time to install The Soundboard, Main Power-Switch and Speaker. Soundboard position Attach the Soundboard. The soundboard is clamped into the soundboard-holder. In addition, a double-sided adhesive tape should be attached under the soundboard. Battery contact wire positions This picture shows the position for the Soundboard, charge-PCB and the wires from both battery contacts.
Page 40 Soundboard - Blade power junction The NeoPixel blade will be powered directly from battery +. So, the wire from battery needs a junction as shown in the pictures. Other option: Most Soundboards have two Vin(+) solder pads. One on each side. Use one for Vin(+).
Page 41 Main Power-Switch TS01CQE Buy it at DigiKey Metal Master 3.0 is designed for TS01CQE 3A switch. This switch can handle high current and is best for Pixel blade sabers. The switch has to be modified first. As shown on the pictures. - Remove one pin.
Page 42 Adding the Power-Switch and charge-PCB / USB port 1. Install the main power switch into the switch holder. 2. Solder the AWG 30 wire from battery positive to the prepared charge-PCB B+ pad. 3. Place the charge PCB in position below the switch holder. No glue needed.
Page 43: Plasma Gate 2.0
Plasma Gate 2.0 The plasma gate is only available for mb-Sabers´ EMITTER Blade holder. Additional parts for the plasma gate 2.0 - 35mm poly-carbonate tube with 10mm outer diameter - 3x 35mm aluminum, steel or brass tubes with 3mm outer diameter - plastic wrap / clingfilm - 3mm LED, 5mm LED or pixel LED / Pixel ring - LED holder / Pixel ring holder...
Page 44: Spinning Plasma Gate (Part 01 Spg)
Spinning Plasma Gate (Part 01 SPG) The Spinning Plasma Gate (SPG) is only available for mb-Sabers´ EMITTER Blade holder. It is compatible with all mb-Sabers Graflex chassis. Old Part01 versions can easily be replaced. It includes a spinning object called the “magnet”. Required additional parts for the SPG –...
Page 45 3D printed steel or cast metal material The Spinning Plasma Gate (SPG) is available as steel or cast/precious metal version. The steel version has two more 3D printed parts! On the pictures below are all 3D printed parts listed for both variations. I recommend testing and adjusting the fit of all parts first, before final installation...
Page 46 Steel part preparation The steel version parts have sprues to avoid deformation. These sprues must be removed. Use a rotating tool or a diamond saw. Also important is to sand down the surface and holes (!) of all steel parts! Tube-holder and SPG ring The steel version has two more parts: The tube holder and the SPG ring (pictures below).
Page 47 Tech-details Remove the sprues from the Part01 SPG tech-details. Put all three tech-details loose over the already attached spacer/steel rods. Electric wire guide tubes Add three thin walled steel tubes (3mm diameter) to Part01 SPG back. Make sure the ends are smooth without sharp edges.
Page 48 Motor section parts Bearings These are the two bearings for the SPG. Assembling the motor section 1. Place the first bearing into the motor-holder. Important: The motor-guide in the middle of the motor-holder must not protrude beyond the ball bearing! Cut it a little until it is slightly lower the bearing level (picture).
Page 49 2. Push the “magnet” onto the motor shaft. It should now look like this... The motor wires can be protected by shrinking foil and liquid rubber. Push the holder (with installed motor and “magnet”) into Part01 SPG back. Install the poly-carbonate tube The poly-carbonate tube is a very important part for the spinning function.
Page 50 Connecting SPG to Part02 To connect the SPG to Part02 a “spacer-ring” between Part01 and part02 is necessary. Otherwise the motor would not fit into the chassis. The spacer is called Part01 SPG spacer. I recommend testing and adjusting the fit of all parts first, before all other work-steps. For all following work-steps the crystal chamber must be completely attached! Now each main threaded chassis rods...
Page 51 Plasma Gate accent 3mm/5mm LED Prepare the LED holder (example) for the PC- tube. Cut down the LED holder. Glue it into the installed PC-tube. (This is just a suggested solution. Actually you can do what you like. It is also possible to stick the LED into the tube...
Page 52 Plasma gate tube Next step is to fill the poly-carbonate tube with something to scatter the light. I would use some plastic wrap. But it is up to you. There are a lot solutions. Do some light tests. If there is to much plastic wrap inside, the light will not shine through.
Page 53: Blade Holder - Emitter
Blade holder - Emitter Backplate Two different backplates can be used. The thin one for NeoPixel setup and the thick version for high brightness LED setup. The thick back plate works as heat sink. Blade stop Two different blade stop rings can be used. A 3D printed nylon version.
Page 54 Switch PCBs 1. Solder the smd switches onto the two PCBs. Add AWG 34 wires later when the Emitter is done. 2. Adjust the PCB thickness. Sand down the PCB bottom a bit till the switch covers fit and work perfectly. Especially the ACT switch PCB should be reduced in height.
Page 55 Emitter Add-On Parts variations IMPORTANT: Depending on which back plate will be used (thick or thin) the appropriate Add-On parts must be used. Add-On parts long for the thick plate Add-On parts short for the thin plate Activation switch “frame” (Emitter add-on B) installation The ACT switch cover is framed by Emitter Add-On B which has to be installed first! Take your time to get the parts in the perfect position.
Page 56 Emitter Glass-Eye adapter - Push the Glass-Eye adapter into position. - Mount it with two M1.6 cylinder head screws. Emitter Add-On D - Separate all Add-On D parts and check for fit. - Add brass wire details and Install each part with a M1.6 countersunk screw. Emitter Add-On E - Separate both Add-On E parts.
Page 57 Emitter installation 1. Connect all wires coming from the chassis to the wires from the blade holder back plate. (High power LEDs or NeoPixel connector) 2. Attach the back plate to the Emitter and connect the switch wires. 3. Install 3x 4-40 UNC 3/4” cylinder head screws into the Emitter mounting holes. 4.
Page 58: Installing The Top Cover Part 06
Installing the top cover Part 06 1. Solder the wires coming from the top cover to the soundboard. 2. Place the tech-details loose onto Part 05. 3. Place the Metal Master Part 06 onto Part 05. Make sure the indicator LED is aligned. 4.
Page 59: Installing The Battery
Installing the Battery Battery installation IMPORTANT: Don´t mix up the poles! 1. Push the spring-contact with the lover edge of the Battery-end (negative pole) into the spring housing. Do not try to push with the center of the Battery- end. It would not work that way. Then tilt the other end with the positive pole.
Page 60 If you have any questions, feel free to contact me: info@mb-Sabers.com...