Go to Rebelscum archive, go to the Sideshow PF section - use the pic of the sword as a cut-out template. Print out the picture twice and paper-glue it to a sheet of thin styrene. Use scissors or scalpel to carefully cut around so you have two sword-shaped pieces of styrene. Then take another piece of thicker styrene and cut it as the "spine" (thicker line that runs the back of the sword length.)
You then have three pieces - two sword profiles in pretty thin styrene, and the "spine" of the sword in a thicker styrene. Glue them together so the two profiles are directly together on the blade side, and splayed/held apart using the spine piece for the back edge (so it's thicker like a real sword.) Place that over the cut-off stump of your existing sword.
I used this method to make a properly scaled (larger) 1/6 Cairo swordsman sword and it looks like a real metal sword.