Stuck blade plug? You’re not alone. Getting a blade plug stuck inside a lightsaber hilt is a frustratingly common problem among custom lightsaber enthusiasts. Here are six possible ways to remove a stuck blade plug.
CAUTION, PROCEED AT YOUR OWN RISK. Unfortunately, all methods for removing a stuck blade plug risk damaging the blade plug and/or the the lightsaber hilt. Before attempting any blade plug removal methods, make sure you remove the blade retention screw from the hilt entirely. Also, always use proper safety equipment (e.g. gloves, safety glasses, etc.).
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1. Long Stick Method
This method may damage the electronics in your lightsaber hilt. If the lightsaber is an empty hilt or configured in as a basic stunt saber, you may be able to slide a stick, chopstick or pen up the pommel end. First, remove the pommel and battery pack from the hilt. Then slide the stick up the open end until the stick hits the bottom of the heat sink. Be careful not to harm wiring or any of the electronics with the stick. Gently push the heat sink up with the stick, which should push the stuck blade plug out.
2. Prying from the Side Method
This method will scratch or damage the side of the blade plug. Remove the blade retention screw from the hilt. Insert a small screw driver (or safety pin, thumbtack, paperclip etc.) into the blade retention screw hole and jimmy the blade plug up little by little. Pull the stuck blade plug out of the hilt using your fingers or using pliers. The prying method could also be applied through windows in the emitter (if applicable).
