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Via: instructables.com
The second time Luke fought Vader, he wasn’t using his father’s old lightsaber anymore – he had constructed a new one. In Return of the Jedi: Beware the Power of the Dark Side!, a new canonical book for kids, it emerged that between Cloud City and Jabba’s Palace Luke was searching for parts that he would later assemble into the new weapon. The last piece was found in the old Tatooine house of Ben Kenobi. Luke couldn’t have trained with his lightsaber a lot before taking on his biggest foe again.
