Katana design

It was kind of a generic question which might not really have an answer other than “it depends.” Those swords are all forged high carbon, which I assume are 10xx series steels. I wonder if .27” would be thick for an s7 katana with a 28” blade length. I kinda cringe when I think of sharpening such a long blade made from 3v, to be honest.
 
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My personal thoughts, which are worth what you paid for them, is that around .300" is "ideal" thickness in a full length sword. There may be very very little cross section of that sword that remains a full ~.3" when complete, but I think it's optimal because you keep that thick cross section where it's needed the most around the handle junction/tang shoulder(whether for strength or balance reasoning), and it gives you a lot of options when it comes to tapering and profile shape.

But I also don't think .188" necessarily sub optimal. It simply constrains how much taper and freedom to profile you have.

That opinion may be completely worthless because I don't know anything about swords outside what I've read and my colloquial understanding, looking at it from the perspective of a machinist, I'm almost always going to want more stock than necessary because I can always take more off.

Ken, for your bevel grind I definitely think you should do a flat grind and slight convex. I only hollow ground my Waki because I happened to be making it when I got my first 12" wheel and thought "why not try it out."
 
I use .250" to .365" stock. As Kuraki said, most all of that gets ground/forged away. The shinogi is the only place with any thickness. It ends up on a 28" katana about .250" at the finished shinogi.
 
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