Khal takes Sarn up on his offer. "We'll have to work together, but I believe it time I made my saber a bit harder to notice. "
For the next few hours before they hit orbit, Sarn and his droid help him with the components. When they are set, Khal starts the long process of recrafting his lightsaber. Any of the crew in the area see Khal in deep meditation as the various parts flow around him. The lightsaber comes together part by part until he completes the whole saber. He then checks the blade emiter, power adjustment nob, and finally how the pieces come part. In the end, the lightsaber is a bit more basic then it was, but is more akin to larger length laser welder . Breaking into two pieces, he could easily hide it from most officials.
Sarn seems pleased in his part, but Khal just remembers something he ordered a while back for the mission "Hey Captain, did the SpecOps quartermaster before we left the fleet give you a package for me?"
[inset response here]
When the ship gets taken out of hyperspace, Khal get the feeling of dread again. When he sees the Imperial taskforce, he is surprised, but not worried. He goes and places his lightsaber (in two parts), and the newly acquired supplies into the containers as requested.
He has his pistol on his his hip holster, to keep up he is more of a Security guy on the ship. When he gets a look from Sarn, he says "I'm your bodyguard or Security chief if asked. I can play that role all day long."