Recently I’ve just been playing around and trying to get it all working, and I think now I’ve got it. I have all the blade pieces cut out, I just need to add the hinges and the blade edges that the center blade catches on, then put the outer layers on. But after that I have to figure something out with the body... any tips or ideas? I wasn’t thinking straight when I cut my wood cause my middle layer doesn’t have the circular piece at the end for the body like yours does. I have the same size PVC as you though, 1 1/4” as the biggest. What do you recommend for the body and attaching everything to it?Sorry for the delay of getting back to you. Must've had the page open cause the notification never pinged that I got a new message =/
Anywho, I do have a picture that has most of the measurements here except for the little hole area, just eyeballed that one for proper size:View attachment 254791
As for the blade, it actually comes from the main cut out here (I know it's the foam version, but it's the same design I used for the wood one) You cut out these triangle sections and they get sandwiched between the outer layers of wood. Don't attach them back to the center piece of wood. To get the angle I used a router with a 45 degree bit :View attachment 254792
The pins are a little tricky to explain, but it goes like this. You're going to need 2 holes on each outer section and one hole for each middle section. The way it works is when the section rotates on the hinge the middle hole will line up with one of the 2 outer holes, respectively for sword or scythe mode. I know this picture will do little, but it's the best I have as this is hard to see when the blade is fully assembled:
View attachment 254793
So what you see is the pin in the one hole, which is the sword mode. When removed the hinge will allow the middle board to rotate and line up with the other hole behind it. It's easiest to mark the sword mode holes first, then taking the outer boards off and rotating the sections to scythe mode and marking those holes afterwards. It took a lot of careful and precise placement to get this right.
Lastly, for board thickness I went with Common Board from Home Depot. Measures 72" long, 11 3/4" wide, 3/4" thick. Hinges were only 3/4" wide as well to fit the middle board.
And no, questions like this don't bother me at all man. Just happy I can help fellow builders =) Do wish I still had the original wood version though, would make explaining it a little easier as I could take more pics, but I had to make space this summer so it had to go.