Amount of time to create new lightsaber

[DB 2.0]

5,000BBY it takes a month to construct a Lightsaber using a Next Generation Power Cell, "Hand Cut" Natural Crystals that are aligned and calibrated by "hand" using only your Force augmented senses your to judge your progress.

come 50BBY after a month of Lightsaber Shop class (and any time after that) you nip down the Hardware (or the Temples Q-Store) and pick up the parts (and any tools) you need, spend most of the weekend "Forging" the Synthetic Crystals, slap it all together run a calibration test, make any adjustments then fire that puppy up and your good as gold. If you already have the Synthetic Crystals siting around you could wip one up in an afternoon.

of cause Luke monkeying about in Ben's workshop likely didn't get the Crystals right first go or the electronics working from "Lightsabers for Dummies", "Zen and the Art of Lightsaber Maintenance" and Ben's vintage "Popular Mechanics" and Holo-Marble "Jedi Channel: Ultimate Lightsaber" collections.

[Volar the Healer]

The few times I had a player construct a lightsaber, I had him make a very difficult roll using his lightsaber construction skill once / day (after aquiring the three parts) until he succeded. Whether it took a few days or a month, and whether it required a force point to succeed or not was up to the player.

I always attempt to use the original rule structure without a house rule if at all possible. The simplicity of the rules is part of what makes D6 great.
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[Quetzacotl]

Well, some official rules do exist to that:
http://d6holocron.com/wiki/index.php?title=Lightsaber_Construction

The Wiki Entry is based on some original rules, as someone from my group pointed that out to me. Would have to search for it if you want the source...