I'm new here so bear with me.
It looks like you violated one of Achilles' Rules to Custom Saber Creation in:
Achilles' Lightsaber Walkthrough (
http://www.lucasforums.com/showthread.php?s=&threadid=129450).
About half-way down the tutorial, there is this:
ModelVariation - this number of the saber model. Referring back to our code resource, we see that the game already uses 01-19. You will need to pick a unique number between 20-99.
I hope that I was able to help in some small way.