Kewl Design Alert: Authentic Handmade Star Wars Lightsaber (video)
Some dude who blogs at Slothfurnace has machined the most incredible light saber replica. There are 7 pages of hi-res pics and I highly recommend that you flip through them because it's pretty amazing. For example, the blade contains 90 LEDs, with custom-made clamps. Everything is hand-made. And incredible.
The video below shows the blade in action, with sound: