Managed to work on this today, luckily there are some detailed breakdown instructions online that helped with removing all the screws and pins to be able to take the blade out. All but three of the screws are visible without any dismantling, there is a single hidden screw under the thumbscrew plate on the top of the hilt, and two more under the clamp covers. Also the wires to the switch had to be cut to allow the inner electronics to be removed, but was easily soldered back on when rebuilding it and won't have to be removed again in the future.
Before starting the breakdown:
Starting out was easy - just remove each visible screw and put to one side. When it got to the clamp though things became much harder, it was held together with a smooth bolt that had a pin through the end of it, which was kept in place by a flat washer with a sprung washer underneath it keeping the fixing under pressure. I couldn't remove the pin, only managed to hammer it halfway through (and in doing so scratched the paint on the clamp), so I ended up cutting it off with a Dremel. The hilt needs some TLC as there are some marks and small areas of missing paint so the scratch will be dealt with when it's next dismantled for painting.
After removing the inner core that contains the electronics there are two pins that have to be hammered out which retain the blade, and after that it simply slides out. Here is the final breakdown showing all of the parts (the screws are in a tub and not shown).
When putting the core back in there was a small sticker which has two silver marks on which needed to be placed back in the correct position as these marks are visible through the slots in the underside of the hilt.
The blade has a DIN plug (7 outer pins, 1 inner pin) although most online photos show it with a molex style connector, apparently the DIN plug is found on earlier versions of this lightsaber as the production was changed partway through to use a molex connector instead. The DIN connector is great though, as it allows the blade to be plugged back in firmly and without having to fumble with molex connectors on wires.
Hilt, blade, and the two retaining pins which kept the blade in place.
Hilt ready for display.
Hilt only, showing that sound functions still work perfectly.
Hilt and blade demonstrating that the blade still works when plugged back in.
And here it is with the E-11 blaster and Stormtrooper helmet.
All it needs now is a stand, I should be able to get one laser cut in clear acrylic pretty cheaply.
Dan