Assemble the front modules and install in the gauntlet.

The fiber optics are how this kit achieves a universal fit. Small differences between designers or armor scales are absorbed by the natural flex of each strand — the fibers bend slightly without any adjustment needed. For larger geometry differences, gentle heat lets you curve the bundle so the tips align precisely with each nozzle opening. A few seconds with a heat gun or hair dryer on low sets the new shape permanently.

LED Housing

The LED housing holds the three rows of addressable LEDs and mounts magnetically to the push arms. It must be assembled and clipped to the push arms before the fiber optics are sized — the installed position determines the correct fiber length.

1. Glue the cover magnets. Super-glue a 3×1 mm magnet into the pocket on each inner and middle row dart mount cover. These mate with the push arm tip magnets installed in Stage 02.

   

2. Route the LED strips. Starting with the inner row, press each LED strip into the housing channel. The fit is snug — do not force it. The blue diode on each LED must face forward (toward the nozzle). Work from inner to outer row.

   

3. Secure the LED covers. Place the dart mount cover over each row’s LEDs. Apply a small dab of hot glue at the center of each cover to hold it in place. Using only a center dab allows the cover to be removed for solder repairs without damaging the strip.

   

4. Attach to push arms and test. Connect the LED housing to the push arm magnets. Verify all three rows attach and detach cleanly. Arm and disarm the system — the housing should travel smoothly through the full stroke with no binding.

   

Fiber Optics

The fiber optic strands carry LED light to the dart tips. Each strand is sized in the gauntlet — thread it through the nozzle first, then cut at the tip opening. One strand sets the length for the rest of its row.

1. Glue the nozzle mount to the gauntlet. Apply a bead of adhesive to the top face of the nozzle mount and press it firmly against the underside of the gauntlet nozzle. Hold until set. The mount positions the gearbox so the dart rows align with the nozzle holes — take time to get this right before the adhesive cures.

   

2. Dry-fit and glue the rear retaining clip. Clip the gearbox into the nozzle mount to find the natural resting position of the rear of the unit. Mark where the retaining clip sits against the gauntlet interior, then remove the gearbox, apply adhesive, and glue the clip at the marked position. The retaining clip keeps the unit centered and prevents fore-aft movement.

   

3. Attach the activation magnet to the hand plate. Affix the 20×10×3 mm magnet to the back edge of the hand plate using a removable adhesive — hot glue or painter’s tape both work well. With the gearbox mounted, tilt your wrist up and confirm the magnet reliably triggers the reed switch. A natural wrist-up motion should arm the prop without accidental triggering while the gauntlet sits flat.
4. Insert one fiber uncut into the first hole of a housing row. Feed a single uncut fiber optic strand into the first hole of one LED housing row. Do not cut anything yet — the fiber needs to be routed through the nozzle while the gearbox is mounted to find the correct length.

   

5. Clip the gearbox in and route the fiber through the nozzle. Thread the fiber through the nozzle opening, then hook the front of the gearbox onto the nozzle mount and press down until it clips in. The fiber is now in its final operating position. To remove the unit at any point, lift slightly at the front and push from the rear to unhook the clip — you will be doing this several times during sizing.

   

6. Power on and arm to find the fully extended position. Turn on the prop and use the activation magnet to arm it. With the darts fully extended, the tip of each fiber should sit at the end of the nozzle opening. This is the reference position for all cuts.
7. Cut the first strand to length. With the darts extended and the fiber seated in the nozzle, cut it just past the tip of the opening, leaving a small amount of excess to trim during final shaping.

   

8. Size the remaining strands per row. Use the first cut strand as a template to size the remaining fibers in the same row outside the gauntlet. Repeat for the middle row, then the outer row.

   

   

   

9. Heat-mold the bundle. Tape the fiber optic strands into the channels on the Fiber Optics Heat Mold tool. Apply gentle heat — heat gun, hair dryer, or hot water — to reduce the natural curl so the bundle enters the nozzle with less friction and applies less load on the servo. Check progress frequently and do not overheat.

   

Dart Tips

The dart tip is sanded to a point then fitted with the printed Beskar-style collar 2 mm from the tip. The sanded end transmits the LED light directly through the fiber; the collar gives each dart its screen-accurate silhouette.

1. Sand the tip to a point. Using 400-grit sandpaper, shape the end of each fiber into a tapered point. Sand in small rotations; check the profile frequently.

   

2. Glue the Beskar collar. Apply a small amount of super glue and slide the Beskar tip collar onto the fiber, positioning it 2 mm back from the point.

   

Final Assembly

Clip the LED housing to the outer-row push arm, tuck all wiring clear of the gear train, and install the wire cover. This is the last step before the prop is complete.

1. Integrate the front module. Connect the LED housing assembly to the front of the gearbox.

   

2. Clip the long push arm. The long push arm has a hook built into its end. Hook it over the outer LED row, then push down and forward to snap it in place. To release, pull it back toward the unit.

   

3. Manage remaining wires and install the wire cover. Tuck all wires neatly into the housing so nothing sits in the path of the moving gear train. Seat the wire cover.