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Revamped for better printability and assembly.

separated blade and handle (they now connect with a tang like a real sword)
added varaiations of the print for different sized printers

The files are organized by various printer sizes. Print all the parts for you sword in the folder matching your printer size. If the part says sym in the title then print two of them (this means they are symetric).

Gluing:

I recommend using pla and superglue. There are small alignment holes that are the right size to insert a snip of .175mm filament. If your printer first layer height is a bit close then these holes will be too snall and you can widen them with a small drill bit. With a little piece of filament in each hole you can snap your halves together. This makes it easy to align the parts together accurately when gluing.

Combining the Blade and Handle:

Once the blade and handle put together and the glue has dried you are ready to put your sword together. Test the fit of the tang into the handle. If it is too tight, then sand the tang on the blade until it can slide in snugly. After they fit together then press the blade all the way into the handle. The pin holde in the tang and handle should align. You can now push a bit of filament all the way through the handle and tang acting as a pin holding the two together. If the holes are too small I recommend widening them with a small drill bit. You can glue the handle and blade together, but I find the parts hold together well without gluing.

Leather handle wrap:

I recommend leather wrapping the handle. Get some long strips of leather. You can cut strips in some nice leather, or (I did this) cut some long strips out of an old belt. Whever you get them start at the bottom. Glue (with superglue) the bottom of one strap to the handle and let it dry. They pull the strip tight as you wrap it upward to the top. Then glue it again at the top. If your strips are shorted and you don't make it to the top, then glue the strip where it ends, and follow up with another stip until you reach the top.

Modifications:

I used onshape to create this model. As a non-commercial creator you can get a free account. You can clone my project in onShape on and make your own changes.

https://cad.onshape.com/documents/9631db5402b082d31e6017e8/w/538d7a6f714d6af0542e94c5/e/a1b92e4b0bddb882e276efc6?renderMode=0&uiState=650092d7aa820071c0615236

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Blade shape adjusted.

Parts separated and sliced for printability on different printers.

Made handle and blade separate and connected with a tang like a real sword.

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Sokka's space sword (Avatar the Last Airbender)

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