Updated Sword Design
Good day, this updated sword design puts the cut onto the "sword edge" so as to hide the seam on the dark part of the design. The process as I imagine it to be is (after cutting) to just fold it in half, line up the faint dark gray guideline and sew the side. The next step is to patch the top by sewing the "U" profile on top. Since the foam is rectangular in profile, the cover should hug the foam firmly. If you can make the top part of the foam a little bit concave instead of being flat, the cuts can be manipulated to match it so it would look better. I also found out that swords with wider ends match your design better than pointed ones, much like claymores instead of traditional swords. The dimensions here are also still the same (30"L x 3"W x 1.5"D). Let me know if it is a bit better design-wise and sewing-wise. Your feedback is greatly appreciated. Thank you.