Wow, the set is beautiful! I love how you added the wavy tempering along the edge, it adds that little touch to make the blades seem more convincing.
I've been trying to find out how to make a clear blade from plexiglass in case I ever get around to a cosplay I want to do. I've never made a sword before, though, so maybe I should try making wooden ones first.
I don't know exactly how thick the blade would need to be, but from what I've seen/read from other people's attempts at this particular sword, no one has bothered to shape the blade realistically. I've only seen one version with a somewhat convincing edge, but I think it was factory-made. Is the plexiglass for your ronin set 1/4", like the Adamants?
Any ideas/tips on how to work with the acrylic? I think I would probably have to use a thicker sheet of plexiglass, or shorten/widen the blade to make it more realistic and less likely to break. Maybe a combination of the two. Refs for the sword I want to make: [link][link][link]
Well making a plastic blade is pretty easy if you have the right tools. Practice on scraps.
Start with a piece of 1/4" Plexiglas. Use a template to draw 3 curves. The blade and the taper point. Cut it with a jigsaw with a fine toothed blade. Now cut and peel the paper on the plastic to reveal the part to be tapered. Shape it with a belt sander with the coarsest belt you can get. Taper it to close to a sharp edge. Do not work one part too long or you will melt the plastic.
Start hand sanding with a sanding block with 80 grit sandpaper and take out all the marks from the belt sander and sharpen the edge.
Remove the paper. Now with hand held sand paper sand out all the scratches using 120, 180, 220 grit.
Next wet sand it with 400 then 600 grit. Dry off the blade. If you want a tampered look cover the edge with masking tape cut to a wave pattern. Now with a polishing wheel and plastic rated abrasive polish the blade, again move the blade so as not to over heat one area.