Katana handle and parts

thingiverse

These are 3D-printed handles for Katana made of aluminum, using a vinyl door sweep from Home Depot as a base. The specific door sweep used is available at http://www.homedepot.com/p/Frost-King-E-O-1-5-8-in-x-36-in-Aluminum-Brown-and-Vinyl-Door-Sweep-B59-36H/100118625. Print Settings: Rafts: Yes Supports: Yes Resolution: 30 micron Infill: 20% Notes: Spacers: Align two door sweeps and check if holes are perfectly aligned. If so, print three regular spacers and insert them between holes in the sweeps to prevent shifting. Once spacers are inserted, connect two pieces together with masking tape, making one pass over the top and another over the "sharp" vinyl side of the blade. Tips: Glue together left and right parts of the tip (two halves are much easier to print without supports as one side is flat). Insert the tip between sweeps on a tip end and align notches to fit into two holes, preventing it from shifting or falling off. Handle: Remove 170mm worth of vinyl from the handle side and push the main guard part of the handle halfway through. Interlock with the end part of the handle and pull through to align the pin hole with the hole on the door sweep. Push a pin through to hold the handle in place - you may need to file the metal through the hole and a pin to avoid breaking the handle as you push it through.