The first very thing you should do is take your flashlight, lightsaber hilt (from here on out, I will refer to it as a saber), and some pliers.
Take the top of the flashlight off carefully with your pliers. You don’t want to break or permanently damage anything if possible at this point. After you have removed the top, you will see a plastic ring.
Take the ring off and save it if you plan to use it later; otherwise, discard it.
Now put your saber into the flashlight tube carefully, making sure that no part of the connection point to the battery chamber is touching any metal parts inside or outside the flashlight body. You should be able to twist the pink lightsaber in if you are putting it incorrectly.
Take your hot glue gun out and set the flashlight on something that the glue won’t damage.
Quickly put your flashlight top back on, pushing it down to ensure it stays in place while the glue sets. If you mess up the connection point or get any hot glue on other parts of the saber, no problem; pull it apart and redo this step without turning the saber off again.
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Be careful not to burn yourself or handle the glue while it’s hot.
When the glue has cooled and completely set, turn your saber on to see if it works. If so, let’s move on to the next step.
If you did not get a solid connection point and therefore got no light from your saber, or it did not stay on, do not try to fix it now. Instead, turn the saber off, let the glue set completely, remove the hot glue from around where you messed up, and try again.
Once your saber is working, put some self-adhesive velcro on one end of your black electrical tape.
Take your lightsaber hilt outside or to a place that the adhesive won’t mess up. Cut notches in the electrical tape about an inch long and a half-inch deep-going from end to end of your saber, marking where finger grooves go.
Cut these finger grooves in the light side or dark side of your lightsaber hilt, depending on what kind of look you want. Continue to cut the notches down.
Now take your self-adhesive velcro and place it in between each notch you made on your lightsaber hilt.
When you are done, turn your saber on and make sure that it works with the electrical tape connecting to the velcro-like before moving on to the next step. If it doesn’t work or you can’t tell, test it by plugging it into the bottom of the flashlight.
Now comes time to put your lightsaber hilt together. The first thing you want to do is take the ring that held the flashlight top on and slide it around where your blade will go being sure not to cover up any parts of the connection point.
Next, use your hot glue gun again to put a bead of hot glue around the edge of the ring that is around where your blade will go, just like shown in the picture. Make sure you don’t get any on your lightsabers body or battery connection point. Let this cool completely and set before moving on.
Now comes time to put your lightsaber together. Take the top of the flashlight and slide it back onto where you put your ring, being careful not to cover up any part of the connection point.
Now take your blade and slide it into the hole in your lightsaber until it is level with the saber’s body, then pull it out a little way.
Take your heat gun and put a small bead of hot glue around the edge of your flashlight’s top, where it will go on to the lightsaber. Be careful not to get any on your lightsaber or electronics! I used the flashlight top in this picture because my top broke when I tried knocking it off like you would with a regular blade.
Put some self-adhesive velcro on the bottom of your lightsaber hilt, just like in the picture.
Put the top of your flashlight back down onto your saber and twist it in, remembering not to put any pressure around the connection point.
Let this cool for a little bit; when it is cool, turn your lightsaber on to make sure that it activates when you hold it with the velcro attached to your fingers.
When you are confident that it is working correctly, let fill in any spaces around your lightsaber’s hilt that might not have had enough hot glue with some more. This will help ensure that the top will stay on and your lightsaber won’t fall apart if you hit something too hard.
Now take your electrical tape and cut another piece the same length as the first.
Use this piece to cover up any of the velcros that might show on the front side of your saber, just like in the picture. This should keep any light from coming through that you don’t want to show up when using your lightsaber.
Take this piece and put it over top of any electrical tape that might show from when you covered up your velcro with some more electrical tape to ensure that no light can come through. This should make a nice clean finish on the front side.
Go ahead and do this to the other side as well. The only difference is that you won’t use any electrical tape on the inside of your lightsaber as you did on the front because there wasn’t enough space.
Now take some more self-adhesive velcro and put it along one edge of your light saber’s body about an inch from the top and the bottom of the lightsabers body.
This will be how your handle attaches to your lightsaber hilt so that you can hold it better.
Put some self-adhesive velcro on both sides of a piece of plastic or anything else you have that is about three inches by two inches long also along one of the edges. This will be how the blade attaches to your lightsaber hilt so that it can slide back and forth.