Cold Steel Bokken Saya

This is a version of Jared Jones' Cold Steel Bokken Saya in GrabCAD that's sliced for small printers like the Creality Ender 2 Pro. The original model does not fit my Cold Steel Bokken, so I had to edit the hole of the saya in Tinkercad so that it can fit. This model does not fit the bokken and will have some gaps but it will be tight enough to hold it in place. 

Scabbard Pieces

The sliced scabbard pieces were labelled into numbers from 1-7, wherein Scabbard piece 1 is the opening of the saya and Scabbard piece 7 is the closed end of the saya. 
 

I'm unsure if Cold Steel bokkens have consistent shapes so I recommend printing the scabbard test piece or the stopperv3 first to make sure it fits yours.

Links

The link connectors for each scabbard piece are placed in folders indicating the Scabbard pieces they connect(e.g. folder “Link 1-2” contains link connectors that connects Scabbard Pieces 1 & 2). They are based on Dovetail connector designs. I highly recommend to print the links in groups of 4 so that you will not misplace the connectors into that for other Scabbard Pieces. 

I did not consider fitting tolerances so I highly recommended to sand them down and/or test out which connector connects to what slot first before connecting them with another scabbard piece. I labelled the links in each folder with numbers 1-4 to know how they're placed. I hammered the connectors to make them fit in the slots tightly. 

In case you misplaced the connector in the wrong orientation or slot, I was  able to remove mine by placing a cutter knife in the gap between the scabbard pieces to push the connectors out.

You can leave the connectors as is or if you want to plastic weld the pieces together, you can do so with a used soldering iron and some extra plastic. I recommend making small holes before running the soldering iron around the gaps and inserting extra plastic. I think it's better to use the same material as the scabbard. Just make sure that you don't push in the melted material into the path that the bokken will pass through.

The aftermath may look ugly at first but it can be sanded down to shape and painted according to your liking.  

Stoppers

I lost my bokken's rubber stop so I included stoppers that will fit the opening of the scabbard. I just thought it would be cool, so I added stoppers with cross guard designs based from European sword designs. I also added a guard design that will add a tonfa-like handle onto the bokken.