My Light Naginata Project

[Ninja-Jedi]

i think cooper is on to something with his idea, the weight should not be an issue if done right he is not saying to use 1/2 flat stock as is, he is just stating to use 1/2 raw materail sand and shape it your liking remember if you use to thin it will crack cause it has lower impact rating, resin would work but there is also a product that bonds polycarbonate into one peice chemically i forgot the name i will post link to it when i find it

[ice]

Unless you end up sanding it down to 1/4" it's not a good idea to use 1/2", which would defeat the purpose of 1/2" anyway.  You are obviously open to due what ever you want, but keep this in mind.  I just weighed a standard 36" ultra blade.  137 grams.  Then I weighed a 1'x6" piece of polycarbonate. 358 grams.  In order to make a full sized blade, you would need alot more then that, probably around 600 grams.  If you wanted it to be 1/2, then it would be 1200 grams.  That's equivalent to about 5 saber hilts.  Talk about the most unbalanced saber ever.

[Ninja-Jedi]

you would want a thick base but the blade itself would prob less then 1/4 inch  also here is a link to solvent welding in relation to bonding plastic such as lexan and polycarb, it would be alot of sanding which would be tedious but little bit less of a chance i knicks and cracks on the edges

<a href="http://www.youtube.com/watch?v=hT6Ow_cBTps" target="_blank" class="aeva_link bbc_link new_win">http://www.youtube.com/watch?v=hT6Ow_cBTps</a>

[DarthCooper88]

 Thanks guys for the education, I was playing with his idea for katana blade as well (I think a show blade is about as far as you would want to go with one of these) , too bad nylon didnt come in a glass clear