Disney Infinity Star Wars Lightsaber Ultimate Pack

How do you unlock his lightsaber via a statue in the hall of heroes?

It is a unlock when you get all 29 regular figures.

Yes, you need all 29 figures (not crystals), and level up them so there's a bronze statue for each character in the Hall of Heroes. They don't have to be silver or golden, it'll unlock once you have all the statues acquired (again, not counting crystals). That should do the trick.

Oh, so that's what the Sheriff sounds like.
Also, that's pretty cool! Ralph is now a step closer to becoming a Jedi!

What level does the characters have to be? Just beyond one? Or level 15

At least level 1, so the statues show up.

Off topic but how on earth do you have so many vault spins available?

leveling all the figures and doing their challenges nets you a ton of spins (18 per character).

Just my opinion, but the best melee weapon is still the Frying Pan... and not just because Rapunzel is my fav... well, mostly not just because.