Hi, Maurice! Love your work on this. I'm about to start work on Gisen Yagyu's scissor sword from Hyakka Ryouran Samurai Girls and had almost the exact same method in mind.
One question though that I didn't see answered: how much does it *weigh*? I thought about using 1" thick softwood planks because MDF felt heavier... but MDF is more easily formed; I prefer it as a construction material. Thanks!
The Blade wheights about 900 gramm (1.9 pounds) so its not that heavy, actually I think it´s a pretty realistic wheight.
Personally I definitely prefer and suggest MDF over softwood planks. MDF is easier to machine and you get a smoother surface. The wood texture of softwood planks can cause difficulties in that. And if you seal it with resin it get´s more durable.