Control Rods

Parts breakdown:

A - common "bright" nail B - # 8 finishing washer (Lowe's 791798) C - 1/4" finishing washer (Lowe's 806705.5) D - # 16 finishing washer (Lowe's 791808) E - 1" washer (Lowe's loose washer bin) (3x) F - SAE flat washer 5/16" (Lowe's 03858) (4x) G - 10mm SST flat washer 810302.5 (2x) H - Lowe's loose washer bins (2x) I - 1/2" aluminum tubing (Home Depot Hardware aisle) The rods pictured to the right are actual LucasFilm props as seen at the Magic of Myth exhibit.

The quantities listed above indicate how many you need to make one tool/cylinder, not the number of packages you need to buy. To make three tools, multiply accordingly.

Start at the top, but skip the nail at first. Take great care to center properly. It's easy to end up with a lopsided layer cake if you don't.

Superglue B to C. The point of contact is very small, so to reinforce it, shoot hot glue in from the bottom to fill in the inside of Part B. Do the same to attach Part D.

The remaining washers have bigger contact surfaces, so use superglue until you've attached all washers. The head of the nail may have surface imperfections. If it does, just dremel or file them away.

Now insert the nail--you may have to hammer it through the hot glue. If it comes through crooked, drill out a bigger hole through the center so the nail is unhindered.

Now put the assembly upside down, with the end of the nail pointing up at you. Again, line it up carefully and fill the inside with hot glue. Not all the way to the top just yet, this is just to get the nail stable.

Now the aluminum rod. Using a table saw, hacksaw or dremel, cut off three 5" sections. File one end of each piece until you have a smooth edge and above all make sure the edge is straight. The other end is unimportant, as most of the rod will be hidden in the pocket.

Back to the nail. If you want to be able to remove the washer/nail assembly from the rod in the future, you can simply wrap the nail with masking tape until you can just barely push it inside the rod. However, there will be a little bit of a gap between the bottom washer and the top of the rod. For a more permanent option, forego the tape and just lower the rod section over the upturned nail.

Verify that the rod rests flush with the washer, file some more if necessary. Dribble some superglue down the open end of the rod to make it stay. Don't overdo it, as the glue will run out the cracks between the parts and mar the outside.

Once dry and the rod stays put without support, drip hot glue down the opening. Let it fill up the remaining area inside the washers and past the joint to the rod.

With a very fine grit sandpaper, you can get the aluminum rod to shine quite brightly. With a bit more work you might be able to get the washers to as well.

Control Rods - Alternate Version

If you don't want to make the rods yourself, contact Richie's Armor. They sell solid resin reproductions of the original prop. Their control rod is pictured to the left.

Belt / Leg Straps

Simply several lengths of 2" wide elastic, painted gray with fabric paint. All the closures are velcro, so the buckle on the front doesn't really buckle.