TINY KATANA

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.

• Metal plate 100mm*50mm*1.8mm
• Bras plate 60mm*60mm
• Popsicle sticks
• Files
• Needle files
• Marker pen
• Vernier Caliper
• Dremel tool(optional)
• Coping Saw
• Sand papers (120,180,200,400,600)
• Vice
• Super glue
• Drill Machine
• Drill Bit (1.5mm)
• Aerosol spray paint
• Electrical insulating Tape

• 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.

• Repeat the steps we did in the previous steps(scabbard) for the handle.

• 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.