To quote one of the mods on CS Forum:
There is no "design flaw" that caused the sword to come out of the handle- it was operator error, pure and simple.
That sword was abused from the outset. What sort of stuff was done to that sword that we did not see on the video? Splitting logs? Seriously? What do you think is going to happen to the sword?
Note that when he was smashing things around his office, no one was wearing any sort of safety gear- not even safety glasses. What kind of idiot smashes a coffee maker (all glass, plastic, and electronics) and does not even wear safety glasses?
During the sequence where he chops the kid on the alter, you can clearly see that the pommel is missing. Was it removed? Did it break? We do not know, but that is a huge safety hazard. Even though that sequence was obviously staged, why would you waive around almost 7 pounds of sharpened steel that can fly out of the handle because a part is missing.
I actually like the show, and I think Daniel Tosh is hilarious, but the gross abuse and complete lack of safety precautions with something as potentially dangerous as a 2-handed great sword is not at all funny.
I happen to agree with the mod. This sword was not only abused, but did you look at all the bystanders around Tosh as he swung and hurled the sword? Moronic.
And what happened to the pommel? Break? Unscrew? Removed intentionally? No one knows, so why don't we leave supposition behind and look at a few facts:
1- He does not know how to swing the sword.
2- All swings were for the "cheap seats" with no control or understanding of how to care for the sword or bystanders.
3- No, CS vids do not show them chopping great big logs with that sword- CUZ U DON'T DO THAT WITH A SWORD!
4- What was done to the sword that we did not see?
I know that the haters are just going to eat this up, but I do not see this as a failure of the sword (again, did he take the time and effort to examine his weapon after abusing it to insure that the f'in pommel had not come loose?), but rather a really poor example common sense and a total lack of respect for what that big mother can do.