Masamune construction! (Posted 15th October 2010)
Sandwiched 2 hollow poles in between the base of the wodden handle, which will then allow the upper half of the blade to slide into place. This sword is 293 cms so it's going to have to be two pieces. The shape of the blade is pointed at the bottom and flat at the top like a traditional katna blade. I've used 2 pieces of mounting board for each side of the blade and filled the bits in between with pollyfilla expanding foam to keep it nice and strong.
Also added the hand guard, but seeing as it's only 1 layer of mounting board I'm going ot give it a good 5 coats of pva before properly attaching it to the handle.