For my project, I decided to tap into my love for videogames and built the Saw cleaver from Bloodborne. It took me about two weeks with a lot of hard work.
Step 1: Making the Handle (pre-shaping)
I started out by measuring the width of my hand so I could find the best diameter for the handle. When I found an decent sized tube which was about 23 in long, I began to make markings at the places I would have to bend it. It was tough to get good estimates from my reference image.
Step 2: Making the Handle (shaping)
After I made sure that the marking were in about the right places, I used a heat gun to bend the pipe at the correct places and cooling it off with cold water so it retained it's given shape; this took a few days to shape it to what I wanted it to look like. Since I just eyeballed it, I can't give any angle measurements.
Step 3: Creating the Blade
I used an X-carve to make the blade from a 0.73 in piece of plywood. The blade is about 19 inches long and about 8 inches wide from the outward most points.
Step 4: Putting It Together
I had to put a notch in the handle to allow for a spot for the blade to pivot. It was quite difficult to get it right and took a lot of trial and error. The notch is about 2 inches deep and about 0.8 inches wide.
Step 5: Finishing Touches
When I finally got it together I started to paint the blade with a silver paint to get a more metallic look. I also wrapped the handle and the pin with black electrical tape.