Thanks for the reply. That is very helpful.
While working with the 3D model - I used that figure (6mm thickness on the metal part of the handle) and came up with a length of 1031.2mm, or about 40.6 inches for the in-game version of the sword. My previous (gu)estimate was 39 inches, or about 990mm.
In the link below there is a pic of the
SHORT version of the sword.
http://fortress.militaryblog.jp/e336220.html
If you translate it you can see that the short version is said to be 20cm shorter than the sword from the game. Using other pics I've managed to find on the net - I've put them next to each other (resized and scaled via image editing software) and can guess that it is the BLADE that is 20cm shorter, not the overall length.
Here's a link to more detailed pic of the handle section. I can't seem to find a photo of the
whole sword in 1 pic that is flat and at a high resolution.
http://static.giantbomb.com/uploads/original/1/10798/2595033-metalgearrising_artbook_page14.jpg
...and, fwiw, a pic/rendering of the LONGER in-game sword.
http://www.deviantart.com/art/Raiden-s-HF-blade-465931028
So.... If the thickness of the (metal part of the) blade would be 60mm - then I shall go with that and make it 40.6 inches.
Unless anyone else has anything else they'd like to add...? I will check back later.
Just to note: That blade does have 3 layers.... I can't say I've ever seen a knife or sword made like that before.
Useless info.: There are other replicas of that sword available (either to buy or view) on-line. But, you can really see the differences in the fine details... AND, I have no idea what method they used to arrive at the length they have for their versions. I've seen various lengths from 38.75", 39", 100cm, 48", and some versions with the blade straight

(no curve to it at all)....