"The exercising of weapons putteth away aches, griefs, and diseases, it increaseth strength and sharpeneth the wits, it giveth a perfect judgment, it expelleth melancholy, choleric, and evil conceits, it keepeth a man in breath, in perfect healthe, and long life." – George Silver (1599)

Japanese katana can have exquistite handguards or tsubas. Auction catalogues of the most beautiful specimens shows the amazing craftsmanship of their creation, when one uses chisels to “paint metal”. These videos which show a modern recreation of a missing tsuba to pair the existant wakazaki tsuba are fascinating.

Chanel makes armor
chanel fashion samurai armor
Bottle armor!bottle armor
Dogs get armor!
samurai dog armor

I think this is an interesting product, used to modify katana-modeled shinai into something more like a longsword.
They are made by Ardenwood Forge.
shinai western longsword hilts
That being said, at Mu Ryu, we’ve made basket hilts for shinai out of the hard plastic used for “pickle barrels”. The barrels are cut with a dremel tool or shears. They offer excellent hand protection, with low weight, while the plastic can be trimmed to adjust balance. And they costs virtually nothing to make.
shinai guard mu ryu plastic

http://www.instructables.com/id/Building-a-Lightsaber/