saberz Project M Chassis User manual

Project M Chassis Installation Guide
Version 1.9.5_b –September 18, 2022 •Page i
Saberz Project M Chassis Installation Guide
Version 1.9.5_b –September 18, 2022

Project M Chassis Installation Guide
Version 1.9.5_b –September 18, 2022 •Page ii
Contents
1Disclaimer and Important Starting Notes..........................................................1
2Chassis Models ..................................................................................................2
2.1 Supported Features .................................................................................................... 2
2.2 Chassis Set Parts........................................................................................................ 3
2.3 Button Functions ........................................................................................................ 3
3Required Parts ..................................................................................................4
3.1 Suggested Parts List ................................................................................................... 4
3.2 Wire and Component List............................................................................................. 5
4Preparation Steps .............................................................................................6
4.1 Hilt Preparations......................................................................................................... 6
4.2 Chassis Preparations ................................................................................................... 6
4.3 Wire Preparations ....................................................................................................... 6
4.4 Battery Sled Preparations ............................................................................................ 6
5Recharge Ports (RCPs)......................................................................................8
5.1 Preparation ................................................................................................................ 8
5.2 Wiring and Installation ................................................................................................ 8
6Shtok NPXL PCBs (Version V3 setup) ..............................................................13
6.1 Prepare the NPXL PCBs...............................................................................................13
7Battery Sled Installation .................................................................................15
8Speakers .........................................................................................................17
8.1 Preparations .............................................................................................................17
8.2 Speaker Wiring and Installation ...................................................................................17
9Power and Auxiliary Tactile Buttons................................................................18
10 ProffieBoard Install and Wiring....................................................................20
10.1 Suggested Wiring Diagram..........................................................................................20
10.2 ProffieBoard Pads ......................................................................................................20
10.3 ProffieBoard Install ....................................................................................................21
11 Post-Install ..................................................................................................23
11.1 Important Reminders .................................................................................................23
12 Adjusting and Securing the Power and Auxiliary Buttons ............................24
13 Important –Chassis Insertion and Removal Instructions ............................25
14 Additional ....................................................................................................26
14.1 Example ProffieBoard Removal Process ........................................................................26

Saberz Project M Chassis Installation Guide DISCLAIMER AND IMPORTANT STARTING NOTES
Version 1.9.5_b –September 18, 2022 •Page 1
1Disclaimer and Important Starting Notes
Disclaimer
-Perform your chassis installs at your own risk. These instructions are intended to only outline and suggest the
installation process we followed to successfully perform installs on this chassis set.
-These instructions are NOT intended to replace the vendor documentation for any of the electrical components
described in this document. It is especially important you read and become completely familiar with all vendor-
provide instructions and documentation. Be sure to download and carefully read the ProffieBoard and NPXL
documents from the vendor.
-Read and understand this document completely before moving forward with your install. All steps are very
important. Failure to read this document completely (and not following the steps correctly) can result in damaging
your chassis, hilt and/or electronic components!
-It is assumed you, as the installer, have experience with soldering, wiring and proper handling of electronics and
follow all safety protocols.
-Exact instructions for soldering the wires to your ProffieBoard are not provided, only the wiring diagram we used for
our installs.
-Never use a heat gun anywhere near this chassis set as PLA, SLS (and resin) printed parts are sensitive to heat.
-Please use care when doing your install! We are not responsible for any damages done to your chassis set (and/or
hilt) by you or your installer during the install process.
Important Starting notes
One of the biggest mistakes when installing a chassis is 1) using too much glue and 2) not providing extra length of wire
for all components (speakers, tactile switches, NPXL PCB, the ProffieBoard etc..). This is critical for supporting future
servicing of components which can go bad. Using just a small amount of gap filling type superglue will provide full
adhesion of the parts, and yet will allow the removal of the part when the bead of glue is broken with a razor. Over-
gluing components will result in destruction of the chassis when said parts are attempted to be removed, such as when
needing to be replaced (e.g. if a speaker goes bad). Additionally, not providing extra wire for all components will result in
not having enough room to solder on a new part, such as a blown speaker or defective NPXL PCB. This chassis set is
designed with enough room inside to allow extra wire for all components.

Saberz Project M Chassis Installation Guide CHASSIS MODELS
Version 1.9.5_b –September 18, 2022 •Page 2
2Chassis Models
There are two versions of the Saberz Project M chassis (one for 24mm speakers and a new version for 28mm speakers):
Standard:
- Designed for 24mm Smuggler’s Outpost speakers
- 1.3mm RCP port under the emitter-side rivet.
- M6*8 chassis retention screw (part of the speaker-side rivet)
- Supports 7/8 NPXL blades.
Hero:
- All features of the standard version.
- Designed for 28mm Smuggler’s Outpost speakers. Requires modifications to the 28mm speakers as seen in the
following YouTube video:
https://www.youtube.com/watch?v=E5NMMniEBG8
2.1 Supported Features
-ProffieBoard v2.2
-Designed using the Keystone 18650 battery sled for fully removable batteries
-External 1.3mm recharge ports (for use with 1A 3.7V Li-ion smart charger)
-24mm speakers
-Shtok V3 NPXL connectors
-The chassis pair will be completely and firmly anchored in place within the hilt by a “retention rivet” (which is part of
the chassis kit)

Saberz Project M Chassis Installation Guide CHASSIS MODELS
Version 1.9.5_b –September 18, 2022 •Page 3
2.2 Chassis Set Parts
The chassis set is offered 3D-printed in SLS material. What’s included:
-Two 3D printed SLS custom chassis.
The following parts are included with the Saberz Project M hilt:
-Two high-impact fully painted and weathered kill keys in high-impact Delrin (for emitter-side silver rivets).
-Two aluminum RCP hex-driven rivet RCP covers (to protect the RCP port when kill keys are not in use).
-Two custom speaker-side aluminum hex retention rivet screws (used to firmly secure the chassis into the hilt).
2.3 Button Functions
-Emitter-side red button - PWR
-Emitter-side silver button –AUX
-Center red and silver buttons –hilt coupler retention screws.
-Emitter-side rivet –RCP
-Speaker-side rivet - Retention

Saberz Project M Chassis Installation Guide REQUIRED PARTS
Version 1.9.5_b –September 18, 2022 •Page 4
3Required Parts
3.1 Suggested Parts List
This chassis set was designed for (and tested with) the following suggested parts. Remember two of each part is needed to
build out both chassis for the Project M Darth Maul staff saber.
-Saberz Project M 3D-printed chassis set kit (2), available from the following:
oSaberz.com Shapeways store
oSaber-Fights Etsy store
-Proffieboard v2.2 (2)
-SanDisk or Patriot (suggested) SD card (2).
-SHTOKCUSTOMWORX NPXL V3 HILT SIDE PCB CONNECTOR –LONG PINS (2)
-NPXL LED PCB Lens Covers (2)
-Keystone 18650 battery sleds (2)
-Brass tactile switches–(4) This chassis set is designed for 1.7mm (0.4mm plunger height).
-Speakers (both chassis models were developed for the following specific Smuggler’s Outpost speakers:
oFor the 24mm version of the chassis (2):
Smuggler’s Outpost Elite 24mm 2w 4ohm Bass Speakers
oFor the 28mm version of the chassis (2)
Smuggler’s Outpost Elite 28mm Elite 2W 4OHM Bass Speaker
Charger - 1A 3.7V Li-ion smart charger with 2.1mm plug
-1.3mm recharge ports (2)
-1.3mm recharge port adapter (1)
Batteries (2) - Sony Li-Ion 18650 3.7V 15A 3120mAh PCB Protected Rechargeable Battery
-Alternative:
https://www.illumn.com/18650-keeppower-3120mah-sony-us18650vtc6-protected-high-discharge-button-top-
p1831r-r-series.html
-Suggested Micro USB Cable Cord –required to fit into SD card connector on the ProffieBoard within this chassis:
A to Down Angle Micro B - Down Angled Micro USB Cable - 1x USB A (M), 1x USB Micro B (M) - Black (USBAUB2MD)
Glue –We have great success using gap-filling super glue (in very small amounts) for all areas of this install requiring
glue. It provides a very strong hold, and at the same time allows the removal of parts where needed (example given,
if a speaker blows or if a NPXL PCB goes bad and needs to be replaced). This is the exact product we use:
https://www.amazon.com/gp/product/B0000DD1QQ/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

Saberz Project M Chassis Installation Guide REQUIRED PARTS
Version 1.9.5_b –September 18, 2022 •Page 5
3.2 Wire and Component List
-WYCTIN 60-40 Tin Lead Rosin Core Solder Wire for Electrical Soldering
-22 AWG wire (recommended):
-Red –NPXL power (+)
-Black –NPXL and Battery power (-)
-28 AWG wire (recommended):
-Red –Board power (+)
-28 AWG wire (recommended):
-Red –power (+)
-Black –power (-) and switches GND
-Green –Speaker (-)
-White –PWR (+) tactile switch / Speaker (+)
-Yellow –AUX (+) tactile switch
-Violet –DATA
Soldering note –set the soldering iron temperature to recommended settings per electronics vendor
documentation.
Additionally, after soldering each PCB is it suggested to use an appropriate PCB cleaner to remove residual flux
before installing these parts into your chassis. We use WD-40 Specialist electrical contact cleaner spray with great
success. NOTE: Be sure to allow this product to completely dry before inserting a battery in the chassis!

Saberz Project M Chassis Installation Guide PREPARATION STEPS
Version 1.9.5_b –September 18, 2022 •Page 6
4Preparation Steps
4.1 Hilt Preparations
Unlike other Darth Maul sabers, no modifications are required to the Saberz Project M hilt. The only adjustments required is
the tuning of the plunger screws underneath the power and auxiliary buttons which is covered later on in this document.
4.2 Chassis Preparations
If using FDM be sure to sand away any flash left behind after removing support structures. No sanding or modifications are
required if you purchased the SLS version of this chassis. In any case be sure to check fitment of all electronics as follows:
-Emitter opening –Test-fit an assembled NPXL PCB in this area before starting the install.
-The ProffieBoard holder area –Note this area was intentionally designed for the proffie to tightly “snap” into place.
Be sure to sand any raised edges along the ProffieBoards and then ensure they press-fit into place.
-Test-fit the speakers into the speaker holder areas at the inner end of the chassis.
4.3 Wire Preparations
Braid the speaker wires and red PWR wires in advance of the install. This can be quickly and efficiently done by securing one
end of the wires to be braided in a vice and the other end in a drill chuck. Then spin the drill until the braid is nice and tight.
4.4 Battery Sled Preparations
-Cut off the metal tabs (seen on the bottom of the batter sleds) so the unit will fit into the chassis, (this can be done
easily and cleanly by bending the extended parts of the tabs back and forth until they break off).
-Cut off the plastic nubs on the bottom of the sled.
-Sand (just) the bottom of the sled using 120 grit sandpaper to ensure the underside is completely smooth and to
allow the sled to sit lower in the chassis.

Saberz Project M Chassis Installation Guide PREPARATION STEPS
Version 1.9.5_b –September 18, 2022 •Page 7
-It is also recommended to carefully sand along this area of each side of the battery sled. Just enough to help prevent
the chassis from slight expansion once the batteries are inserted:
-After sanding is completed clean the sled with a little rubbing alcohol to remove sanding dust residue.
-Pull out and tin the (+) and (-) tabs with solder and place the tabs aside for later use when the hot and negative wires
will be soldered on.

Saberz Project M Chassis Installation Guide RECHARGE PORTS (RCPS)
Version 1.9.5_b –September 18, 2022 •Page 8
5Recharge Ports (RCPs)
5.1 Preparation
-Remove the metal bracket from the front of the RCP and discard. This part easily pops right off.
-Carefully shave off the small plastic tabs located towards the front of the RCP:
-Test fit the RCP into the chassis.
5.2 Wiring and Installation
Important! Be sure to plan on soldering the wires on the RCP in the direction seen below. It is very important the wires are
oriented this way once the RCP is installed into the chassis: