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:

Saberz Project M Chassis Installation Guide RECHARGE PORTS (RCPS)
Version 1.9.5_b –September 18, 2022 •Page 9
Wire the RCP as seen follows:
-Two RED 28 AWG wires to the (+) tab (braided together).
-Use enough wire so one can be later connected to the (+) on the battery sled (which will be directly next to the
ProffieBoard area of the chassis) and the other will be later connected to the BATT (+) pad on the ProffieBoard.
Wire one each of the following:
-BLACK 22 AWG wire (short wire) later on for (-) on the battery sled.
-GREEN 22 AWG wire (long wire) later on to the BATT (-) on the ProffieBoard.
Wire orientation:

Saberz Project M Chassis Installation Guide RECHARGE PORTS (RCPS)
Version 1.9.5_b –September 18, 2022 •Page 10
After soldering the wires to the RCP it is suggested to use small lengths of heat tubing to secure the wire
connections:
Completed shrink tubing for the green 22 AWG, black 22 AWG and red 28 AWG twisted pair:

Saberz Project M Chassis Installation Guide RECHARGE PORTS (RCPS)
Version 1.9.5_b –September 18, 2022 •Page 11
-Since the soldered connections on the RCP are very small and somewhat delicate it is important to protect them
with a thin application of hot glue which will fully secure them. This prevents damage to the small RCP welds
later on during the install process. Important! Failure to do this will likely result in the welds breaking from the
movement of the wires during the install!
-Also curling the green wire before installing the RCP will provide additional (and much-welcome) ease during the
ProffieBoard installation later:
Important! Before installing the RCP into the chassis, note the RCP opening is situated closer to one end of the RCP
housing. The image below indicates the required orientation in which the RCP needs to be facing. Failure to situate
the RCP as seen below will result in the recharge port hole not lining up with the RCP opening in the hilt!

Saberz Project M Chassis Installation Guide RECHARGE PORTS (RCPS)
Version 1.9.5_b –September 18, 2022 •Page 12
-Install the RCP properly and secure it in place with gap filling superglue.
-Once the glue is fully dry (and cured) carefully add a bead of hot glue to fully secure the RCP in place. Use a small
(just enough) amount of hot glue as seen below:

Saberz Project M Chassis Installation Guide SHTOK NPXL PCBS (VERSION V3 SETUP)
Version 1.9.5_b –September 18, 2022 •Page 13
6Shtok NPXL PCBs (Version V3 setup)
Disclaimer: As with all components, be sure to reference, study and understand the owner’s manual from the PCB vendor.
6.1 Prepare the NPXL PCBs
-Carefully sand the outer edges of the NPXL PCB unit to verify fitment into the emitter side of the chassis.
-If you did not purchase assembled NPXL PCBs you will need to solder the pins onto the PCBs.
-Test-fit the NPXL PCB again (this time with the clear PCB lens on) into the emitter end of the chassis. The PCB
should snap in and stop solidly at the thin raised inner ring which keeps the PCB at the correct placement.
Carefully push the PCB back out using wood dowel or eraser side of a pencil. Be sure to remove the plastic lens
from the PCBs before the next steps of soldering on the wires.
Soldering warning from the PCB vendor (links below):
WARNING! DON’T OVERHEAT THE PCB WHEN SOLDERING!
-When soldering pins to the Pixel blade connector, make sure to not overheat the PCB, as this will damage pixels.
-Since there will be no accent LEDs for the metal “LEDs” seen on the side of the Project M Darth Maul hilt use the
following V3 configuration:
oLeave the on-board 330-ohm resistor in place on R2.
oBridge the J pad.
oRemove the resistor on the R1 pad.
Finished examples:

Saberz Project M Chassis Installation Guide SHTOK NPXL PCBS (VERSION V3 SETUP)
Version 1.9.5_b –September 18, 2022 •Page 14
-Solder the required wires (as seen in the wiring diagram at the bottom of this document) to the proper pads on
the bottom of the NPXL PCB.
-Clean off the PCB with an appropriate PCB cleaner to remove residual flux before proceeding. We use WD-40
Specialist electrical contact cleaner spray and lightly brush around the soldered pads with a light bristle
toothbrush.
-Gently attach the plastic lens to the PCB.
-Form the NPXL PCB wires into a “spring” (by tightly wrapping the wires around a paint brush handle) as seen
below. This will allow slack in the wires and ease of removal if you ever need to replace the NPXL PCB:
-Carefully push the NPXL into place into the emitter. Later on (and after testing the completed chassis), use a
couple of really small dabs of gap-filling super glue to keep the lens in place.
Important! Be sure the NPXL PCB is oriented as seen in the below image, (with the NPXL PCB rotated so the wires are
located on the inner-most side of the chassis). This provides needed space for connecting the Micro USB connector
to the ProffieBoard later on in this area:

Saberz Project M Chassis Installation Guide BATTERY SLED INSTALLATION
Version 1.9.5_b –September 18, 2022 •Page 15
7Battery Sled Installation
Note: Study the wiring diagram at the bottom of this document to become completely familiar with the battery sled wire
locations. Before starting, note the (-) side of the battery sled will be situated at the speaker-side of the chassis and the (+)
side will be located next to the ProffieBoard area of the chassis:
If not already done, remove the battery (+) and (-) tabs from the battery sled before soldering the following
connections:
Battery sled negative:
-Trim the (short) 22 AWG BLACK battery (-) wire from the RCP to a length just long enough to be able to wire it to
the negative side of the battery sled.
-Solder this connection (to the loose negative metal tab which will be slid back into the battery sled later).
Battery sled positive:
From the twisted pair of RED 28 AWG wire from the (+) on the RCP;
-The first RED 28 AWG wire will go from the RCP to the positive metal tab on the battery sled.
(The second RED 28 AWG wire will go from the RCP to the Batt + pad on the ProffieBoard (in a later step).
-Solder on the RED 22 AWG wire (from the NPXL PCB) to the positive metal tab on the battery sled (in the exact
same spot as the above RED 28 AWG wire from the RCP).
-Slowly lower the battery sled into the chassis, making sure the wires underneath stay in the center channel to
prevent them from being pinched under the sled.

Saberz Project M Chassis Installation Guide BATTERY SLED INSTALLATION
Version 1.9.5_b –September 18, 2022 •Page 16
After fitting the sled properly in place, secure it with a small amount of gap-filling super glue.
Important! Once the glue has dried, use hobby tweezers to slide some of the green/white twisted wire back into the
speaker compartment (just enough to provide enough wire slack for later on if you need to replace a speaker in the
future).
Future note: At the end of the install, (and after the chassis is completed and tested), it is suggested to add a final
amount of gap-filling super glue to fully secure the battery holder into the chassis.

Saberz Project M Chassis Installation Guide SPEAKERS
Version 1.9.5_b –September 18, 2022 •Page 17
8Speakers
8.1 Preparations
Use the (previously prepared) braided length of 28 AWG GREEN and WHITE which should be long enough to go from
the speaker-end of the chassis past the ProffieBoard area at the other end of the chassis.
-White for positive (+).
-Green for negative (-).
Use a razor to remove any tabs or imperfections which could interfere with a nice flat fit of the speaker against the
chassis:
8.2 Speaker Wiring and Installation
-Solder the green wire to the speaker prong with the red mark (+) and white wire to the remaining prong (-).
-Route the braided speaker wire pair into the wire channel under the (future) battery sled and over to the
ProffieBoard area.
-Secure the speaker into the end of the chassis with a small bead of gap-filling super glue (or e6000 glue).

Saberz Project M Chassis Installation Guide POWER AND AUXILIARY TACTILE BUTTONS
Version 1.9.5_b –September 18, 2022 •Page 18
9Power and Auxiliary Tactile Buttons
The tactile switches need to be installed before installing the battery sled as wires for the AUX switch will be routed
under the batter sled.
Solder 28 AWG BLACK and YELLOW wire onto the prongs on one switch, and 28 AWG BLACK and WHITE wire onto
the other switch.
-The white and black set will be used for the PWR button.
-The yellow and black set will be used for the AUX button.
Important! Before proceeding note the tactile switches need to be installed directly against the inner portions of the
tactile depression as follows:
-Carefully route the wires through the wire holes (keeping in mind the soldered connections on the tactile
switches are very delicate)!
-Install the black/white set (for power) in switch the depression closer to the emitter.
-Install the black/yellow set (aux) in the switch depression further from the emitter.
-Use a very small dab of super glue in the switch holder and carefully press the switches into the holder.