Hey there,
For the people about to receive/order their Square shroud saber kits, I wanted to give a bit of a how to for assembly
The kits come with the core already attached as well as the pommel ring already glued, so you don't have to do this
Square shroud saber kit Assembly
The grips/clamp:
We have less references of this particular version and people are free to come to their own conclusions. To me, the grips are 92mm long, end angled at 30° and the clamp is resting on top of them at around 93mm from the base of the tube (before the pommel ring).
I think the clamp is at the 6 o clock position.
If you go with those positions and want to have the bottom hole visible between two grips, you'll have two grips one on each side of the clamp bubble. If you put on grip aligned with the clamp, a grip will be on top of the hole.
Weird thing, I have positioned those two holes on the body tube according to their exact position visible on the Barbican. I have always assumed that those were remnant from the motorized square shroud, so, this version. However, according to what I see on the references and my 3D model, the top hole is hidden under the clamp on that version. So, this stays a mystery to me.
The clamp doesn't have its rubber sleeve on the Barbican, and cast, so I assume that it is the same for this one. Basically, it will work with a just a strip of paper or a bit of tape under the clamp. This will prevent scratching the aluminium tube and will put just enough pressure to close the clamp and hold the bubbles. You may need to test depending on your clamp/bubbles/tape/paper. You can see a bit of a gap under the clamp on the Barbican photos, so it's likely they also put a thin spacer on the actual saber
The body tube diameter is both matched on my 3D model from plenty of references and confirmed from direct measurement on the actual Barbican by a kind soul, so this is pretty safe
The Shroud:
Paint the shroud as you like. I personally went with Tamiya semi gloss black with a semi gloss varnish as well for extra safety.
once dry, please be carefull when assembling it with the tube, the shrouds are a pretty tight fit and we don't want to damage the tube
The tope hole (on the largest flat side) should align with the recess on the body tube next to the set screw holding the core. Once aligned, hold the shroud in this position and put that first set screw. Then you can add the second set screw on the bottom.
The short grip:
You can slightly sand the curve if you like as the curve is just machined and they probably filed/sanded it on the actual saber. The machining is pretty clean though so they can also work as is.
Those go on the same side as the bubble strip, on the smaller flat side of the shroud. It is positioned at about 11mm from the bottom of the shroud.
The activation box:
this goes against the shroud.
I personally attach them with the brass screws as I'm not the biggest fan of glue. But it's up to you to see if you are up to the task of drilling taping for the small screws or prefer to glue everything down.
if you want to use the screws, here is how I go about it:
First, I like to round slightly the bottom of the box. not much, it won't even be visible from the back end, just so we don't see the large holes too much from the bottom.
I then position the box and mark the holes with a pen:
to drill the holes, i use a small handheld drill, not a powerful one, on a rather low speed. I use a 1.2mm drill bit and carefully drill both holes. Then I tap both holes with a m1.4 tap and a bit of oil. Slowly, this is a tiny tap, it can break easily.
(I have done 28 grip screws and 20 activation boxes screws so far though and haven't broken it, but be carefull)
After this, it's just a bit of patience to get the screw into the hole, but it should only take a minute to attach it
After this, you just need to attach the brass bracket in the box. I personally spread both legs of the bracket a tiny bit until it's a tight fit into the box. I apply a dab of glue on each side of the box, press the bracket slightly with my nails to make it fit into the box and push it down.
there you go, that's about it I think!
I hope you'll enjoy building your kit and will love this saber
cheers