This prop is inspired by the menacing macuahuitl, a weapon of ancient America (México). I built it for a friend who descends from the Chichimeca. I discovered a fun new way to use acrylic!

Supplies

2" by 1/2" by 36" poplar board X2

1/4" acrylic sheet

Leather belts and scraps

Leather cord

Sinew cord

Ornamental beads

Feathers

Step 1: Research

"Just Google it!"
- SSG Baum
Look for photos, paintings, cliff drawings, wikis, articles, movie screens, etc, for your desired prop.

Step 2: Put Design on Paper

Draw your design on paper. Don't limit yourself to one drawing. This is about getting what's in your brain, out.

Step 3: Transfer Design to Materials

Measure twice, cut once! Make sure to measure where necessary to ensure accurate transfer of your design. I don't recommend winging it too much. Eyeballing isn't terrible, but it's not always the way. Anyway, draw your design onto your materials.

Step 4: Cut, It, Out!

Cut out your design out with whatever saw or cutting device suits you. I mostly used an inadequate band saw. I also used an old thrift store grinder to cut the spaces between the "blades." You'll also have to cut out another piece of the acrylic to reach the end of the hilt.

Step 5: I Don't See Nothing Wrong, With a Little Sand 'n Grind

Sand the wood to desired shape and smoothness. Sand the acrylic on the edges to bevel it for the "blades." Use a grinder to achieve the look of napping (chipping) obsidian rock. And then, for kicks, why don't you paint the acrylic with some gloss black spray paint. Don't lay it on too heavy. A light layer allows more light to pass through which is typical of black obsidian.

Step 6: Put the Pieces Together

Use glue, screws, nails, hopes and prayers, or whatever you see fit to fasten the pieces together. I used screws. After getting it together, take it back to the sander and grinder to even out the pieces. Make them become as one. It's a beautiful and satisfying thing to behold. Oh, and if you're feeling up to it, drill out a hole in the bottom of the handle for ornamental purposes.

Step 7: Stain the Wood

Do as the title of the step commands. Stain the wood with whatever shade does it for you.

Step 8: Leather, Strings, Beads, and Feathers...

Use a sheet of leather to create a nice soft cover on the hilt. Stitch it together with waxed cord. Use simulated sinew to cover the ends of the leather handle. While you're at it, throw some in the center of the hilt as well. Really, you can do whatever suits you here. Use the sinew to also cover the spaces between the blades, which conceals more of the acrylic underneath. I wrapped it in a criss-cross pattern. And then I just ran some waxed cord through the hole in the bottom of the hilt a number of times. Then I placed the cord through the beads and tied the end off. After that, I poked small holes in the ends of the feathers, ran the cord through them, and wrapped the ends of the feathers together. After the adorning is finished, smother the sinew with wood or paper glue. Let it soak into the layers so as to seal it all together.

Step 9: Weather It

Use a little bit of stain to go over the sinew and wood to give a dirty, or weathered appearance. And finally, hit the whole thing with a clear coat and seal it all together beautifully.