Update 4/30/16 - I have reduced the OD of the chassis by .5mm to reduce friction when installing or removing the bottom half of the hilt. I have also increased the clearance at both ends of the battery to allow space for solder and wire.
EZKit with required hardware and recharge port is available here.
This is the easiest Graflex 2.0 chassis on the market. If you're not able to precisely locate, drill, and tap holes in your saber to install other chassis, then this is the answer you seek. This chassis locks into the grenade section with the twist of a hex wrench, giving you the confidence to duel, cosplay, or just play with the kids without fear of breaking your chassis.
The locking mechanism is simple to use and requires only a 2mm hex wrench. A long T-handled hex wrench is recommended, but ball end drivers also work well. By tightening the screw, you force the locking wedge to expand within the grenade section, firmly securing your chassis. The wire tunnel has plenty of space for all of your LED and switch wiring, and the chassis is removed as quickly and easily as it is installed.
I have designed the chassis to support all known soundboards from both Plecter Labs and Naigon's Electronic Creations.
A location to install a recharge port, in the form of the CUI PJ-051A, has been provided. Minor modification to the port is required, but if you buy an EZKit from me for this installation, the pre-modified port will be included in the kit.
There is sufficient room to install a protected 18650 cell, and the speaker mount holds a 28mm speaker (bass or premium style).