Elegant Weapons Consulaire Mk.1 lightsaber battery cart

This is a replacement battery cart for Consulaire Mk.1 sabers from Elegant Weapons.

While the sabers themselves are very durable and have become a staple in a lot of fencing clubs, the 3D printed battery cart tends to break over time from repeated use. Elegant Weapons used to sell spare carts but no longer do, since the Mk.1 is no longer being produced.

This model prints in under an hour and should be at least as durable as the original cart.

Recommended print settings

• PETG, ABS or ASA
• 3 Perimeters
• 100% infill

Features

• Reinforced handle: the handle at the end has been designed to be extra strong
• Walls close over the battery at the top, thus preventing the battery from falling out when it's not inside the saber.
• Spring contacts: no more breaking contacts, or need to adjust the contacts angle.

Variants

The cart come in two variants:

• lightweight: looks closest to the original cart and is fast to print and uses little filament. It should be enough for personal use but may not be as durable as the reinforced version.
• reinforced: the rounder shape comes with thicker external walls and less overhangs while printing, which will result in a stronger print; material use is a bit higher and the print time is a bit longer.

Additional features

Tab

A “Locking tab” can be added; the tab slides into the handle and matches the profile of the hilt; it prevents the cart from sliding into the hilt and moving around.

Note that this is not compatible with the brass weights.

Ejection tool

You may optionally print a small tool that facilitates removal of the battery. Poke it through the hole in the bottom of the cart to push the battery out if you're having trouble getting it out.

You may of course also use your trusty Allen key for that :)

Bill of materials

You'll need additional supplies to complete it though:

• 16x16.5mm 18650 spring battery contacts; I got them from Aliexpress and the model has been designed to fit these dimensions:

• JST SM 2 pin female connectors and cables; I bought those pre-assembled, since crimping them can be a pain ;)

Assembly instructions

Prepare all the parts.

Once you've printed the cart, you'll need to trim the positive wire from the connector. Take roughly 7cm off.

Then, slide both cables through the holes and strip the cable you just trimmed (it's easier to strip it after routing it through the hole).

Now, solder the positive and negative terminals.

Trim excess solder and wire with a flush cutter, then bend the bottom of the terminals at a roughly 90° angle.

Slide the terminals into the slots at each end, and push them all the way until they are flush.

Done, and ready for battle!