I came across this website put together by one Bradley Lewis, who is not only a video game developer but also builds these replica lightsabers using various found objects and parts that he either alters or machines himself. I have not had a chance to view all of his pieces but the most stunning so far is the Luke Skywalker lightsaber that can be disassembled to reveal a lit crystal chamber assembly and also houses a working soundboard + speaker system that is significantly louder than anything else out there.
I have to say I am extremely jealous on many fronts, particularly of his workshop and spare miscellaneous parts collection. He's also lucky enough to have a wife who encourages him in his endeavors (now if only I'd listen to my wife for this sort of thing - preemptive self-nag - hehehe).
The interior was even signed by Mark Hamill during a Star Wars convention before it was entirely finished. Completely awesome - I highly recommend visiting the website: http://www.slothfurnace.com
