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Picture of Make a

A while ago I made my son a Luke Skywalker costume for Halloween, and at the last minute, I decided I wanted to do a quick photo shoot with him for the cover of one of my YouTube videos. The one thing that was missing from his costume was the lightsaber. In about 4 hours I was able to make a pretty good looking lightsaber using only things I already had around the house. The secret, magical component was the aluminium tape I used. It is incredibly hard to make any paint job look like shiny metal, so adding the tape gave a layer of actual metal over the whole thing. Perfect!

Here are the tools and materials I used:

Pattern: I used the one that I created. You can find it on my website and it's free! Align the crosses on the two pages and tape them together.

Golf club tube: I found these at a local big box hardware/sporting goods store. They cost a couple of dollars each. The smoother the better.

Aluminum tape: This is generally used on ducting. Make sure that the tape you are getting is actually aluminum and not plastic.

Copper Tape: Not totally necessary - I used some leftover from making stained glass.

5mm thick EVA foam: For the flanges on the handle and the circle to close up the back.

1/2” PEX pipe: 10 cm long

3/4” PEX pipe: 10 cm long

Metal coat hanger or other wire

Stack of washers

3/16" Drywall spring toggle bolt

Plastic tray or other plastic you can cut up: 1-2mm thick. It should be flexible and not crack when cut.

Small piece of foam board

Small piece of 2mm craft foam


Sharp Knife: I like to use a surgical scalpel

Metal shears: I used for cutting the golf club tube. Probably not necessary, but makes it really easy.


Abrasive Scrubbing Pad: I used a green Scotchbrite pad.

Hot Glue Gun: I used a hot glue gun. It works in a pinch for a quick build, but I would probably recommend some other glue like super glue or two-part epoxy for long term.

Metallic Paint: I used DecoArt Americana Decor Metallics “Silver.”

Please note, the above links are affiliate links, and I do get a small commission if you buy through these links. It doesn't cost you any more and it helps me out!

Step 1: Safety First!

Picture of Safety First!

Sharp knives, hot glue, and candles can all cause injury and property damage. Don't leave a flame unattended, don't burn yourself, and don't cut your fingers off!

Capt-Chaos4 months ago
I think faux lightsabers are pretty neat and like to read the posts about them, but this is the first time I have ever seen such a detailed and easily explained instructable on them. Great work. You would be a great trainer!
Krell Metal4 months ago
Now THAT was one of the simplest, most impressive Inscrutables I have ever seen and I have made light sabers for industrial light and Magic.
LostWax (author)  Krell Metal4 months ago
Wow, thanks for the compliment!
seamster4 months ago
This is so good! I made some cheap/quick lightsabers using cardboard, craft foam, and various tapes a while ago, and they were a lot of fun (these).

I'm very happy to point out that the quality on yours far surpasses mine! Very nice work!!
LostWax (author)  seamster4 months ago
Thanks for having a look! I just checked out your lightsabers, they are amazing! Love it. Those tubes you used are a good resource to know about as well:)