I saw a program on TV about professional japanese sword making and the guy that making them said "now you woudln't think this is possible with a sword *starts bending it*, but they are actually quite flexible". It didn't look very hard to do. I don't know why you can't do it with your sword. Maybe your is thicker or something.

It's really amazing how they use over 40 different types of stones to make them sharp. Very interesting what long tradition can accomplish over time without any real high tech.

BTW does Bugei have those nice "stick" like disguised swords? Forgot the name for them.