I recently heard back from the manufacturer of my newest blade, which some of you may recall had a broken nakago. I found this upon inspection of the blade. The current nakago ends in a jagged break which is about seven and a half inches in length. The manufacturer stated that the normal length on his 33" O-Katana is ten inches. SO, it appears that the blade was damaged when the tsuka was hammered on in the factory. :(
We'll see how it ends and hope for the best, however. So stay tuned for the latest up date.
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