There are many ways to make your own lightsabers and I am pretty sure most of you can make better one soon. Thanks to the internet that there are so many good people out there are willing sharing their experience and ideas. Follow their footprints I will share how I made them too.
Here are some useful links for where I get these material:
Everything you need to create your saber. They made pretty high quality hilt. Highly recommended.
Custom hilt and all other metal needs. Tube, sheet, angle etc.
This is where I get polycarbonate tube as blade.
I used to make my own control unit to do the visual and sound effects from Beetle, Arduino NANO or Pro Mini, but 'Makoto' made pretty decent module which make everything a lot easier and compact into one small unit . Where to get it? Well, this grand master has his own attitude that he ask me not to provide any information but his name. 'Follow the force and you may found me.', he said.
Again, there are just too many ways to make your very own lightsaber. I also recommend to take a look of Arduino based controller 'Beetle' and 'MP3 Player' from DFROBOT.COM, they are very tiny and easy to use.
The photo above has shown some progress of how a hilt had been done. In this particular 3 color blade I used Beetle + Mini MP3 Player + 3 NPN Transistors. Battery was weld direct on module but I leave USB port open for future re-program purpose. Recharge socket also added in so no need to take the battery out to charge. The MP3 player also pretty handy and easy to use that only require softwareSerial RX/TX to play the sound F/X.
The charger was well designed. You may use any USB port with micro USB connector to connect any device which has 5V USB output to charge the battery inside of hilt.