Shop sequence

Make the object

Electronics are a loom you slide into a turned stick. If the blank is ugly, no firmware saves it. If the laser bore is off-axis, no IMU fusion saves it. Craft first, then current.

1. 01

   Turn the blank

   Start with a 7.25 × 0.85 in oak or ash blank. Turn to 7.00 in finished, 18 mm grip, 10 mm tip, 22 mm pommel. Leave a 0.25 in tenon on the pommel for the cap. Sand to 320, do not oil yet.

2. 02

   Bore the loom

   From the pommel, drill 8 mm to 140 mm depth. From the tip, drill 4 mm × 22 mm for the laser barrel. These two bores meet. A printed mandrel keeps them coaxial — a crooked laser is the whole object ruined.

3. 03

   Split the mid ferrule

   The steel mid ring is a C, not an O: a 2 mm gap so the NFC coil can breathe. Press-fit after the coil is potted. Tip ferrule is a full ring and may be solid.

4. 04

   Loom the stack

   Tip → laser + magnet ring + Hall. Mid → NFC coil. Grip → speaker facing the port, amp, XIAO, LiPo. Pommel → pogo, optional LRA. Wire as a single loom on 30 AWG with a 8-pin JST at the pommel so the cap unscrews for service.

5. 05

   Crystal and aperture

   Turn or buy a 12 mm acrylic or glass drop. Drill 1.5 mm on center. Seat with UV resin, laser on at low PWM while it sets so the beam stays true. The crystal is jewelry and a collimating window.

6. 06

   Wrap, oil, flash

   Leather or cord, 11 turns, sting at the ferrules. Oil the timber. Flash firmware through the pommel jig. First test: dock Hall, BLE advertise, 3 second laser, a chime, a flick-to-wake. Then pair it to the board.