Lightsaber made out of welded steel for my friend Tactic. approx. ten inches long, 1&11/16" in diameter. Does not, in fact, slice through anything.
Stand was done in about ten minutes while I waited for a weld to cool down. A combination of acetylene/oxygen torch welding and MIG welding was used, as well as a few blacksmithing techniques. Handle grooves were done veeeery carefully with a chopsaw.
For more images, both in-progress and finished, go here.