Hi Susie,
Welcome to planDisney and thank you so much for asking us a question, my fellow Canadian!
I completely agree that shipping things home to Canada from the Disney Parks, while convenient, can be quite expensive. You’re in luck, because not only do I fly Air Canada every time I fly to Orlando for my visits to Walt Disney World Resort, but I’ve also had the chance to make a lightsaber with my son at
Savi’s Workshop in
Star Wars: Galaxy’s Edge during one of our trips. It truly was a fun and unforgettable experience.
You have several options for getting your precious cargo home safely. The first, and probably the best/safest one, would be to detach the Lightsaber blade from the hilt or body to make it a little less long. If you have a tall enough suitcase, it should fit inside – the blade is 31 inches (or about 79 centimetres) long. We were able to fit ours into our carry-on luggage by placing it diagonally across the suitcase, and then tucking the hilt beside the blade itself. We used clothes around it as padding and both pieces made it home safely.
The other option would be to keep it in its carrying case and try to bring it on the plane. This option is a bit riskier because it really depends on how busy the flight is that day and on the discretion of the flight attendants who will be serving you during your flight. That said, I’ve seen travellers put their Lightsaber in the overhead bin, and I’ve seen some put at their feet, especially at window seats. Again, that may not be an option depending on where you’re sitting on the plane, so I’d highly recommend trying to fit it into your luggage first.
I hope my answer helps you plan smooth travels to and from your Disney Parks vacation and a Galaxy Far, Far Away! Please don’t hesitate to come back and see us if you have any other questions. We’re always happy to help.
Have a Magical Day,
Lynne