Ok I rechecked it and saw that it wasn't untill "A friend in need" that the sword changed and i suppose that it would have been difficult to reshoot all the scenes where it appeeared before they got the new sword. I also confirmed that not only the blade changed but the handle and guard got a lot smaller. I still hold to my theory that they just had a bad prop for the first several episodes but i would still like to know if there is any farther story on it.
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