Custom Collapsible Sword (Need Help)

[harsh beacon]

Hello, I have been trying to take this model of a sword handle and make it into a collapsible sword for my D&D campaign as well as an addition to my costume for ren fair. I used two separate models and started combining them.
model 1: https://www.thingiverse.com/thing:5479591
model 2: https://www.printables.com/en/model/847802-collapsible-viking-sword-print-in-place-and-replac
I am very new to 3D modeling and only got a 3D printer a few weeks ago. I've tried watching videos and its gotten me thus far but i have run into an issue that I cant find any videos on and I cant afford to keep wasting filament printing these at a smaller scale just to test things out since for the blades that i adjusted can only go down to 75% of their current scale before my printer cannot print them.
For the hole in through the model i resized the blades to fit through all three sections of the handle. I took the bottom blade (after it was resized from the original) and put it into my slicer, made measurements until i have it just larger than the base blade. put it back into blender, covered the holes and made it solid. i then used Boolean tools to create holes in the parts of the model and sized the blades to the full length of the hole.
it seems that the base blade and all the following blades catch too early on the inside of the hole. The white model is printed at 76% while the blade blades are printed at 75% and it helped a little bit but it still catches too early.
I either would like help getting the blades to fit or help figuring out what percentage I should print the blades compared to the handle and compared to each subsequent blade.
funny part is the blades as their own STL don't print in my printer as they are. I HAVE to scale them down to At least 88% for them to fit.
I would also appreciate someone looking at my model to tell if it is clean as i had some gaps on my last print, mainly on the pommel. any assistance is appreciated as its been taking me 3 weeks to get this far

[unborn dagger]

Hey @harsh beacon, thank you for contributing to this forum.
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[harsh beacon]

I can either paste a drop box link or try to put the zip files in the thread if needed

[harsh beacon]

Started to print the pieces of the blade in different %, the base blade is at 87.5%, then 87%, then 86, then 85%. Printed the tip at 84% and it ended up having a curve in the blade. Going to print the tip at 85% or 84.5% soon and reprint the handle 1-2% larger than the base blade. Might also try printing all at 88% or so for testing sake. I am printing the blades in case mode

[astral bone]

theres loads of text and im not into reading tonight hehe

basically

your printer prints anything using layer lines

the layer line shave height and width

if youre printing at .4mm layer width, you gotta make your blade at least .8mm thick

if you make it .799999mm the slicer will read it as only one wall thick, making it easily breakable

when making the blades smaller than each other its kinda a thing you have to figure out how much of a wiggle room your printer has, it doenst print .4 but .4 +- .01mm

https://www.printables.com/model/3719-collapsing-katana-print-in-place

try seeing what this guy made for it to work

look at the model he made

[jovial osprey]

DUDE

you cant capture another persons post like that

and stop crossposting