Zabuza Sword - Kubikiribocho Cosplay Replica

First read the instructions before printing.

This is a multipart 3D model of Zabuza’s legendary Kubikiribōchō sword – fully printable without any wood or metal reinforcements. All structural connections rely on 3D-printed plastic parts, using hex-shaped pins that slot into matching holes inside each segment. The sword is about 1,8 m (6 ft) tall. 

🛠️ Important Assembly Notes

• Blade:

The blade is split into 6 parts and connects via round pegs (⌀ 30 mm, length 100 mm) that insert into 50 mm deep sockets.

⚠️ You need to print the peg 10 times!

Each blade segment is uniquely keyed – do not swap their order, or alignment issues will occur. Always dry-fit the full blade before gluing!

• Handle:

The handle consists of alternating black and silver decorative cylinders, starting with black and ending with silver.

Three silver pieces require supports – if you’re using my Bambu Studio Project, all settings are already applied.

The internal diameter is 25 mm, designed to fit either:

• My 3-part hexagonal stiffening rod, joined together with hex pins (mini pegs)

• A wooden or plastic dowel, 588 mm long (⌀ 24–25 mm), for extra stability

  → If you’re using a thinner rod, just print an adapter to reduce the inner diameter. It works – I promise ;)

Assembly Tip:

Build the handle step by step:

Start with the first (black) piece, insert a hex pin, slide the next silver part onto it, and glue the pin in place. Then add two or three more handle segments, extend with another hex pin, glue again – and repeat until the handle is complete.

This incremental method ensures better alignment and makes the process easier.

Don’t forget: you’ll need a lot of glue for the handle! (See glue tips below.)

I recommend using construction adhesive (also called grab adhesive or mounting glue – fast tack, cures within 24h) together with superglue.
Mounting Glue recommendation for Germany: https://amzn.to/448OWYQ
Super Glue recommendation for Germany: https://amzn.to/3Gcl6cJ

Superglue alone is not enough. Use plenty of glue to fill the gaps around the pins and provide extra stability – but do not overfill the blade holes. A clean, precise fit is crucial for the blade alignment.

🔩 Tips for Best Results

• Always dry-fit all parts before gluing
• Use strong adhesive, especially on structural joints
• Use mounting glue for the handle for extra durability
• Build the handle in stages, one pin at a time
• Print all connectors (hex pins, pegs, stiffeners) with high perimeters and high infill