I haven't made a sheath for it yet, but will post it when I do.
Step 1: Gather Materials and Tools
- 8"x2" peice of metal.
(I used an old machete from walmart)
- saw to cut metal aka hacksaw.
- a couple metal files; flat, rounded, and 1/4" round file.
- sandpaper, grits 60 and up.
- paracord, or whatever 1/8" cordage you've got lying around.
- vise (optional but helps a lot)
- drill (optional if you make a lanyard hole)
- honing stone (optional, but not if you want a sharp blade)
Step 2: Find a Helper
Step 3: Make a Template
Step 4: Cut Out the Blank
To accomidate the blade I used I had to notch above the handle to create enough space to cut out the blank and then had to recut to get the thickness of the handle where I wanted it. Also when cutting the curves in the handle make sure to cut kerfs, being careful to stop just short of the edge, otherwise it requires a lot of filing to get rid of the gouge and may alter the shape you intended. Oh, and if you use a flat blade like I did you'll probablly have to rotate the blade occasionally so the frame of the saw isn't in the way.
An optional step is to drill a lanyard hole in the base.
Step 5: File and Sand
For the blade edge I made only one bevel, leaving the other side flat. Take into consideration which side you want the bevel on, especally if you're left-handed (make it on the opposite side I did).
Next sand off the paper, sand around the edges, sand the edges smooth, sand the file marks off the blade. Start with 60 grit paper, and work up to at least 220. The more care and higher grits you go to the better it will look in the end. You don't really need to worry about sanding off the black coating if you're using a walmart-machete; it'll help prevent rust by leaving as much on as possible but if you take care of it that won't be necessairy.
Step 6: Hone the Blade to a Knife-edge and Wrap Handle
The only thing left to do now is to attach the cord on the handle. This is to make it easier and more comfortable to use as a cutting tool, and also to store the cord you'll need to attach it to a staff, making a true harpoon out of it. Ideally the cord is to be paracord, but if you can't run down to your local army surplus store, just about any 1/8" cordage will do.
To wrap the cord, first hold the ends together and find the middle. Place the harpoon on top of the middle of your cord. make an overhand knot, the same as the first step of tying your shoes. The way I do it the cord on the left will always go under, the cord on the right will always go over. If in doubt study the tying diagram. You can finish the wrap by tying a square knot on one side of the handle (two overhand knots on top of each other) or if there's enough cord, just go through the lanyard hole and make a knot on the other side of it. Tie the two ends together to make a loop.