So, holy crap. When I started, I was completely overwhelmed. A massive thanks to the people on this forum, without whom, I'd have been dead in the water. I spent countless hours lurking, planning, researching, starting to work, then rechecking my math here. I went big for my first crack at it, but I had a specific vision as this was a present for my brother in law, for Christmas. So, without further ado, the pictures...
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Rough cuts of 1", 1 1/4", and 1 1/2" PVC
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Template over 1 1/4" tail piece
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Cute and shaped
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1 1/4" PVC slip to male threaded coupling. This was for the pommel. The slip side was cut down to allow just enough contact to glue on the hilt. About 1/4". The male side ended up being more difficult. The way it is threaded does not allow for the female cap to screw easily all the way down, so I ended up cutting the threads off completely the gluing only the top 3/4" of the threads back on. It's an awful lot of effort, but the final results are pretty good, by my estimation.
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First dry fit.
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