His latest, which took 18 months to build, is Obi-Wan Kenobi's Reveal Lightsaber from A New Hope. It was made with a real crystal, just like the movies, and has a Crystal Focus Saber Core designed by Plecter Labs which controls the light and sound.
The blade is composed of 84 LED lights and powered by two 3.7 volt batteries. Lewis used a "string blade" design so that the saber is equally bright from top to bottom.
He even weathered the parts to make it look like it's been through a battle or two.
After all that hard work, here's the finished product.
And finally, a video of the Reveal Lightsaber in action.
Want to know more? You can find a much more detailed version of Lewis's process on his blog.
Want your own lightsaber, but don't have 18 months to spare? Try out this DIY lightsaber made from scrap parts.