What worked for me is using thin 1.5" o-rings. I placed them in the middle of the "sleeve" section and then installed the sleeve. The o-ring ended up squeezed underneath the middle of the sleeve, not down by the threads. That way it could still thread into place fully, but the pressure from the o-ring creates tension that keeps the sleeve from moving, while wielding the lightsaber.

Got mine last Thursday. Identical pieces to yours except the top grip. Similar experience (cast took it from me and were swapping parts trying to get it to work). Switch ended up being broken (too loose due to a stripped screw into plastic). So I took it apart. Cast member must have stripped it to get it on the first time because everything both top and bottom grip are as loose as yours.

Your "wires" and "lip" are called threads. Your "shaft collars" are called o-rings. Good info for Power and Control builds. I have gone through 3 sets of replacement sleeves and switches with Disney. They even sent a chassis. Nothing works. The metal on the switch is too soft and the threads flatten out. I had the same experience as you in that the new V2 sleeves tighten up perfectly with a V1 switch. Crap production by Disney's vendor. I used the 1 1/2" beveled drain pipe washers. They allow for perfect alignment all around and are hidden completely. The only issue, like you said, is that you need to remove the emitter and pommel cap to gain access to the crystal. The only good that came out of this is that with all the replacement parts, I now have 2 Power and Control sabers. Yay :/

I just mine this past weekend, and the pieces were snug and tight before I changed the crystal now it’s super loose at the top collar kind of disappointing when you pay 200+ for a cheap product went from being super excited once finished building to disappointing once messing with it

Just got back with the exact same lightsaber with the exact same issue.

For the ridiculous prices _DiSNeY_ charges for this crap there really should not be any quality control issues.

Yeah, just built one two days ago and realized that we're screwing metal threads onto plastic threads and those plastic threads wear out. Very cheap design, poor engineering designed for max profit. The only plus is that you get to change the color of you spend more money but they don’t apply that feature in many other ways because they make more profit on the way they designed them.

Hey bro, do you happen to have a link to those washers you used?

I put another o ring on the bottom of the bottom piece and one inside the end piece and it made it line up close.

Same issue happened to me a few months after building mine I always suspected it was the plastic itself wearing away and thas the part losing grip. Though that being said I still don’t want to duel with this until the electronics are refurbished and I can find a better solution to stop the parts from wobbling all I was doing was light motions and the parts end up coming loose. I wasn’t even twisting. Also I know that the Disney sabers are not at all intended for dueling but I really want to duel with them. I did have the idea of building one and then when I have the funds converting it to a better electronics system. Anyone know of someone that does this very well?

Same issue, but it's easily fixable. I get your complaint though.

A yr from now the issues persist 😂😂😂

This happened to mine and i am never going back there again i will just stick with the legacy ones