Yeah you got it with the guide pins, like tooth picks or chop sticks to help align the layers. Would need the thickness (edit: of the material) as accurate as you can measure because the error would add up across lots of layers, down to the 0.000" if possible. Can slice it any direction you want but because it is a purchased file there might be some issues sending it to me even tho i would probably never use it beyond helping you here. If its an issue and you are able to download the program i mentioned before i could walk you through it step by step to get you where you need to go.
I’m assuming it would be best to have one guide pin for the entire length? I’ll look for a thin dowel. I have bamboo skewers, but I am not sure they would be long enough.
I would not go with a thin dowel. I would go with a 1/2" or so. between that and gluing all of the discs together, you’ll end up with something very strong.
@primalhealer I finally got a dowel and measured it in several places. No surprises, it was different in each spot I measured. The widths I measured are: 0.4605, 0.4629, 0.4559, 0.4640, and 0.4825. All for a half-inch dowel! Do you take an average?
An average would work or you can size it to the smaller spot so its a snug but not tight fit so the thicker spots probably fit fine with a bit of force if needed or a quick sanding. Will probably need some tooth picks as well for the end of the saber where the finer detail is.