Summary of Contents for saberz Project M Chassis
- Page 1 Project M Chassis Installation Guide Saberz Project M Chassis Installation Guide Version 1.9.5_b – September 18, 2022 Version 1.9.5_b – September 18, 2022 • Page i...
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Page 2: Table Of Contents
Project M Chassis Installation Guide Contents Disclaimer and Important Starting Notes ............1 Chassis Models ....................2 Supported Features ....................2 Chassis Set Parts ......................3 Button Functions ......................3 Required Parts ....................4 Suggested Parts List ....................4 Wire and Component List ..................... 5 Preparation Steps ..................... -
Page 3: Disclaimer And Important Starting Notes
Saberz Project M Chassis Installation Guide ISCLAIMER AND MPORTANT TARTING OTES 1 Disclaimer and Important Starting Notes Disclaimer Perform your chassis installs at your own risk. These instructions are intended to only outline and suggest the installation process we followed to successfully perform installs on this chassis set. -
Page 4: Chassis Models
HASSIS ODELS 2 Chassis Models There are two versions of the Saberz Project M chassis (one for 24mm speakers and a new version for 28mm speakers): Standard: - Designed for 24mm Smuggler’s Outpost speakers - 1.3mm RCP port under the emitter-side rivet. -
Page 5: Chassis Set Parts
The chassis set is offered 3D-printed in SLS material. What’s included: Two 3D printed SLS custom chassis. The following parts are included with the Saberz Project M hilt: Two high-impact fully painted and weathered kill keys in high-impact Delrin (for emitter-side silver rivets). -
Page 6: Required Parts
This chassis set was designed for (and tested with) the following suggested parts. Remember two of each part is needed to build out both chassis for the Project M Darth Maul staff saber. Saberz Project M 3D-printed chassis set kit (2), available from the following: Saberz.com Shapeways store o Saber-Fights Etsy store Proffieboard v2.2 (2) -
Page 7: Wire And Component List
Saberz Project M Chassis Installation Guide EQUIRED ARTS 3.2 Wire and Component List WYCTIN 60-40 Tin Lead Rosin Core Solder Wire for Electrical Soldering 22 AWG wire (recommended): Red – NPXL power (+) Black – NPXL and Battery power (-) 28 AWG wire (recommended): Red –... -
Page 8: Preparation Steps
4.1 Hilt Preparations Unlike other Darth Maul sabers, no modifications are required to the Saberz Project M hilt. The only adjustments required is the tuning of the plunger screws underneath the power and auxiliary buttons which is covered later on in this document. - Page 9 Saberz Project M Chassis Installation Guide REPARATION TEPS It is also recommended to carefully sand along this area of each side of the battery sled. Just enough to help prevent the chassis from slight expansion once the batteries are inserted: After sanding is completed clean the sled with a little rubbing alcohol to remove sanding dust residue.
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Page 10: Recharge Ports (Rcps)
Saberz Project M Chassis Installation Guide (RCP ECHARGE ORTS 5 Recharge Ports (RCPs) 5.1 Preparation Remove the metal bracket from the front of the RCP and discard. This part easily pops right off. Carefully shave off the small plastic tabs located towards the front of the RCP: Test fit the RCP into the chassis. - Page 11 Saberz Project M Chassis Installation Guide (RCP ECHARGE ORTS Wire the RCP as seen follows: 28 AWG wires to the (+) tab (braided together). Use enough wire so one can be later connected to the (+) on the battery sled (which will be directly next to the ProffieBoard area of the chassis) and the other will be later connected to the BATT (+) pad on the ProffieBoard.
- Page 12 Saberz Project M Chassis Installation Guide (RCP ECHARGE ORTS After soldering the wires to the RCP it is suggested to use small lengths of heat tubing to secure the wire connections: Completed shrink tubing for the green 22 AWG, black 22 AWG and red 28 AWG twisted pair: Version 1.9.5_b –...
- Page 13 Saberz Project M Chassis Installation Guide (RCP ECHARGE ORTS Since the soldered connections on the RCP are very small and somewhat delicate it is important to protect them with a thin application of hot glue which will fully secure them. This prevents damage to the small RCP welds later on during the install process.
- Page 14 Saberz Project M Chassis Installation Guide (RCP ECHARGE ORTS Install the RCP properly and secure it in place with gap filling superglue. Once the glue is fully dry (and cured) carefully add a bead of hot glue to fully secure the RCP in place. Use a small (just enough) amount of hot glue as seen below: Version 1.9.5_b –...
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Page 15: Shtok Npxl Pcbs (Version V3 Setup)
Saberz Project M Chassis Installation Guide NPXL PCB HTOK ERSION SETUP 6 Shtok NPXL PCBs (Version V3 setup) Disclaimer: As with all components, be sure to reference, study and understand the owner’s manual from the PCB vendor. 6.1 Prepare the NPXL PCBs Carefully sand the outer edges of the NPXL PCB unit to verify fitment into the emitter side of the chassis. - Page 16 Saberz Project M Chassis Installation Guide NPXL PCB HTOK ERSION SETUP Solder the required wires (as seen in the wiring diagram at the bottom of this document) to the proper pads on the bottom of the NPXL PCB. Clean off the PCB with an appropriate PCB cleaner to remove residual flux before proceeding. We use WD-40 Specialist electrical contact cleaner spray and lightly brush around the soldered pads with a light bristle toothbrush.
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Page 17: Battery Sled Installation
Saberz Project M Chassis Installation Guide ATTERY NSTALLATION 7 Battery Sled Installation Note: Study the wiring diagram at the bottom of this document to become completely familiar with the battery sled wire locations. Before starting, note the (-) side of the battery sled will be situated at the speaker-side of the chassis and the (+) - Page 18 Saberz Project M Chassis Installation Guide ATTERY NSTALLATION After fitting the sled properly in place, secure it with a small amount of gap-filling super glue. Important! Once the glue has dried, use hobby tweezers to slide some of the green/white twisted wire back into the speaker compartment (just enough to provide enough wire slack for later on if you need to replace a speaker in the future).
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Page 19: Speakers
Saberz Project M Chassis Installation Guide PEAKERS 8 Speakers 8.1 Preparations Use the (previously prepared) braided length of 28 AWG GREEN and WHITE which should be long enough to go from the speaker-end of the chassis past the ProffieBoard area at the other end of the chassis. -
Page 20: Power And Auxiliary Tactile Buttons
Saberz Project M Chassis Installation Guide OWER AND UXILIARY ACTILE UTTONS 9 Power and Auxiliary Tactile Buttons The tactile switches need to be installed before installing the battery sled as wires for the AUX switch will be routed under the batter sled. - Page 21 Saberz Project M Chassis Installation Guide OWER AND UXILIARY ACTILE UTTONS The connections to the tactile switches are very delicate. To prevent these welds from being broken (in later steps while moving the wires around inside the chassis) it is recommended to apply a small drop of superglue or e6000 glue (in the inner-chassis area, where these wires come through the chassis body).
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Page 22: Proffieboard Install And Wiring
Saberz Project M Chassis Installation Guide ROFFIE OARD NSTALL AND IRING 10 ProffieBoard Install and Wiring 10.1 Suggested Wiring Diagram 10.2 ProffieBoard Pads Connect the wires to the under-side as seen below. Remember to bridge LED 2 and 3 as seen in the above diagram. -
Page 23: Proffieboard Install
Saberz Project M Chassis Installation Guide ROFFIE OARD NSTALL AND IRING 10.3 ProffieBoard Install Once you have completed soldering all the connections to the ProffieBoard (for each of the two chassis in this set), you will need to firmly press the 4 corners of the proffie to seat fully into place. - Page 24 Saberz Project M Chassis Installation Guide ROFFIE OARD NSTALL AND IRING o LEDs on the emitter light up. o PWR/AUX button functions work as expected. Once the above testing is completed, perform the following steps for the final task of gluing the ProffieBoard into the chassis: Insert the kill key and remove the battery.
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Page 25: Post-Install
Saberz Project M Chassis Installation Guide NSTALL 11 Post-Install 11.1 Important Reminders Allow all PCBs to be dry and free of PCB cleaner before installing your SD card and batteries. Always use the kill key before inserting or removing batteries. -
Page 26: Adjusting And Securing The Power And Auxiliary Buttons
Saberz Project M Chassis Installation Guide DJUSTING AND ECURING THE OWER AND UXILIARY UTTONS 12 Adjusting and Securing the Power and Auxiliary Buttons Note: The black rubber O-rings (on the PWR and AUX buttons) which came with your Project M hilt will need to be either removed or replaced with thinner O-rings when using a chassis with this saber. -
Page 27: Important - Chassis Insertion And Removal Instructions
Saberz Project M Chassis Installation Guide – C MPORTANT HASSIS NSERTION AND EMOVAL NSTRUCTIONS 13 Important – Chassis Insertion and Removal Instructions It is especially important to follow this exact order, otherwise you could damage the chassis: The below instructions can also be seen in the following YouTube video: https://www.youtube.com/watch?v=_NxufcAojLI... -
Page 28: Additional
Saberz Project M Chassis Installation Guide DDITIONAL 14 Additional It is highly NOT RECOMMENDED to power on a chassis outside of the hilt. Handling the chassis while powered on outside of the hilt with the ProffieBoard (and other electronics) exposed can cause shorts which will destroy the unit. - Page 29 Saberz Project M Chassis Installation Guide DDITIONAL We hope you truly enjoy this chassis set as much as we do. As always. please feel completely free to contact us if you have any questions on the content of this document or anything regarding the install process of these parts for your saber.