Katana is a long, single-edged sword used by Japanese samurai.

I have always wanted to build one. What is more challenging than building a tiny katana.

This katana will be 100mm long scale 1:9. This is fairly simple to make and can easily fit into the palm.

Supplies

Step 1: Katana Blade

Print the template and separate the blade outline from the template.
Glue the blade template onto the metal plate.
Cut a rough pattern of blade using angle grinder or coping saw and separate it from the metal plate.
Use a file to reach proper shape of the blade following the outline of the blade template. Make use of needle files for small material removal.
Once the true outline is achieved place the blade flat and file the faces to remove burrs. Remove the glued paper template as well.
Cover the faces of the blade using a blue marker pen.
Divide the blade into 2 parts by marking a seam using a digital Vernier caliper. In our case this comes out to be 1.5 mm hence make use of digital Vernier calipers for precise measurements and marking.
Clamp the blade by the handle and start filing the bevel till the marked seam as shown in the photos.

Cut the collar rectangle template from the paper and glue it onto the 1 mm brass plate and repeat the same filing steps as we did for the blade.
Hold the cut rectangle in vise jaws with centerline aligning the jaws edge and hammer the cutout to bend it.
Make a u bend out of this rectangle and wrap it to the blade.
Place the blade flat and hammer the collar rectangle to get the shape of the blade. You can heat it on a gas stove for better and easier forming.
Hammer the handle of the blade with collar placed in the blade and on the anvil. This will create a proper rectangular groove.
File the bent collar such that the collar sits half way on the blade and handle.
Cut the extra length of the collar. The inner groove of the collar should resemble the shape of the blade.

Glue the handle template on to the 1mm brass plate.
Drill two holes using 1.5 mm drill in the rectangular section.
File the drilled holes to create a rectangular pocket. I have used a Dremel power tool to do the job.
Cut and separate the circular tsuba from the brass plate.
Do a dry fit and check if the blade fits properly in the guard rectangular hole.

I have used popsicle sticks for scabbard and handle since it can easily be cut and shaped and it perfectly matches the thickness of the blade.
Place the blade on the popsicle stick and align it to the center.
Trace the blade curves on the popsicle sticks.
Using a sharp knife/blade to cut the traced part.
Glue the cut popsicle on other two popsicle on either sides making sure the cut popsicle retains the original shape.
Using a file roughly shape the scabbard into an oval.
Once shaped use sandpapers to sand the scabbard. Start with lower grit sand papers such as 180 grit and gradually increase it.
Spray paint aerosol paint on the scabbard.

Wrap or glue a piece of sand paper onto popsicle stick and sand the blade slowly .
Use lubricants such as wd40 for better sanding.
Start with smaller grit papers and gradually increase it.

I have used a buffing pad that was included in Dremel kit with green buffing compound.

Cut a thin strip (2mm) of electrical insulating tape of the length 30cm.
Wrap this strip on the handle in a helical pattern making sure the adhesive side of the tape is sticking to the handle.