The Sword of Dracule "Hawk-Eye" Mihawk, One Piece (live action)

A friend asked for a full-sized version of Dracule Mihawk's sword as seen in Netflix's live action version of One Piece (2023)

This thing is a monster. It's 1727mm (68") from tip to pommel and 711mm (28") across the hilt. To help with rigidity across such long dimensions, it uses (2) 48" sticks of 1/2" dowel spliced together and cut to length. The leftover dowel is used in the hilt. I have included a splicing jig to help with making the joint. 

Even with the efforts I made to strengthen the design, this is a big, honking, sword. Be careful swinging it around. 

Assembly 

Start with cutting the scarf joints in your dowel and glue the scarf (good old wood glue and clamps works great.) The final lengthwise stick with be ~1478mm (58-3/16+".) You'll also need (2) dowels for the hilt, each about  228mm (just under 9") long. These sticks will meet at the Grip Nut.

Prefit all parts before gluing. 

Blade Assembly: Make sure your dowel can be inserted the full length of each piece and the pieces mate easily. The Blade Connectors in the Blade Base are printed at a different orientation so the layer lines don't match, giving extra strength. 

Hilt Assembly: Start with the arms, making sure the dowels can be inserted. 

The hilt centers on the GripNut. The long dowel passes all the way through the GripNut and the hilt dowels butt up against the long dowel.  

IT IS ESSENTIAL THE LONG DOWEL CAN PASS THROUGH THE GRIPNUT ONCE THE HILT IS ASSEMBLED (or you're gonna have a bad time)

Grip Assembly: Pretty straightforward, just take care to line up the sections properly. Glue the parts together.

Pommel Assembly: Glue the PommelNut to the grip. Leave the pommel until the long dowel has been glued into place and trimmed as needed.

Glue the blade to the hilt, hilt to grip, and finally, grip to pommel.

The HiltTangs go on last, they are printed at a different orientation from the blade so they should provide reinforcement at the join between BladeBase and Blade1.

It was easier to design wall hangers than a floor stand. The hangers are designed for #8 pan head screws and wide enough to cover #8 drywall anchors.

The tag is 3mm thick allowing for color changes at 1.2 and 2.2mm