This is basically how I craft the Matrix Splicer as far as the blade assembly goes. I will discuss the pommel/flashlight retention system later.
I start with the ⅞ inch mid-grade blade.
Next I plug both ends to help prevent dust from getting in the blade followed by sanding the exterior surface of the blade with 150 grit dry sand paper followed by 220, 300, 400, and 600 wet sandpaper (dry can be used, but wet is much easier to apply).
After I finish sanding I take a wet towel and wipe the exterior of the blade.
At this stage I take a dowel and press the paper towel through a couple of times to ensure that the inside of the blade is clean.
After I replace the paper towels, I press the one at the top in and sand the top ¼ inch interior and the shoulder of the blade cap with 150 grit sandpaper in preparation for gluing. I then clean the interior of the blade using the paper towel and dowel method.
Next using the pommel/flashlight assembly and a locking ring on the bottom, I attach the assembly to the blade and find the balance point. Mark it with a pencil.
I then line up the grips to determine the total length that I will need. One of the end rings will be cut to be placed on the inside end of the upper grip.
At this time carefully and neatly cut the grips (this is a reason why the square pattern on the Matrix Splicer grips are nice to install).
Remove the locking ring. Plug the blade again (not shown) and apply Wd-40 to the outside of the blade to the approximate length of the grips. If the grip becomes slippery, push it on with a towel. It is a little difficult and may require standing while having the end on the floor to push the grip on against.
Fine tune where you want the grips while the blade and grips are still wet. Wd-40 when dry will act as a cement for the grips.
Remove the paper inserted into the ends of the blade. Remove the film from the bottom of the blade tip. Having gotten the grips attached, apply a light bead of E-6000 glue to the shoulder of the blade tip. Press firmly into the end of the blade ensuring that the tip seats fully.
Place the locking ring on the grip end
of the blade. Give the glue appropriately 24 hours to dry before significant use of the blade.
Enjoy your light sword!