Another cool weapon from the Star Trek universe is the Klingon Bat'leth. It has been seen in many episodes of The Next Generation, Deep Space 9, Voyager and the comics. I am going to attempt to make one of these.
Finding reference images for this was easy. Finding the measurements was not. The best I could find, was found on HouseVampyr.com.
"Kneel down on the ground (as flat a stretch of ground as you can find). Have a buddy measure you from the top of your head to the ground. This measurement will give you the tip-to-tip length of your Bat'leth".
I do not have a picture of someone measuring me, but I can tell you that my bat'leth will be 53" tall, and I am 5'10" tall. So I drew the shape in illustrator.
And printed it to scale.
Below is an image of my template taped together with a yard stick above it. Next I will trace the shape onto a piece of insulation foam.
Unfortunately my template was larger than my piece of insulation foam, so I cut my template in half and traced it on the foam.
And then I cut the shapes out.
Using my x-acto knife I beveled the edges.
And then I glued the 2 halves together and sanded all the edges smooth.
Next I painted the whole thing with black acrylic paint.
Due to it's size, I had to find interesting places to let it dry.
Once it dried I applied a coat of spackling paste. This will help fill in the porous nature of the insulation foam.
Even after the paste dried, the Bat'leth was still wobbly, so I added some cardboard to the surface to make it more sturdy.
It worked well and now it's quite sturdy.
Once it dried I sanded it, cleaned it up and then gave it a coat of black acrylic.
Next I used some gripping tape to wrap around the handles.
Then I took it outside for a layer of filler primer.
It unfortunately got caught between some furniture I was moving around and got mangled. But I'm not overly upset. Materials are inexpensive and I can easily make a new one. I've also since gotten better with wood working, so I decided to make a new Bat'leth out of wood. I used my old template and printed out and cut half of the sword.
I gathered some leftover wood, hoping that I can make the whole thing out of scrap.
Unfortunately this would probably not work out well since all my wood pieces are too small.
So I bought 2 large pieces of wood and traced my template on one of them.
Next I cut out the shape with my jig saw.
Then I used that shape to trace out the second side.
After about 15 minutes of cutting, I had my 2 halves.
To join them I drilled pocket holes.
Then I glued and screwed them together.
I glued in plugs where the pocket holes were.
When the glue dried I sanded the areas smooth.
Next I used a round-over bit on my router to give the edges a rounded edge.
Then I applied some wood filler to a few spots that needed filling.
Next I gave it a coat of dark gray primer.
This sealed up a lot, but I also was able to see much more that needed filling. So out comes the wood filler.
When the filler dried I sanded.
Then I sprayed on some more primer. This time it was light gray.
The primer is doing it's job well. The whole thing doesn't have wood grain showing through. 2 small areas needed additional touch up, so back to the wood filler.
When dried, I sanded again.
Then one last coat of primer.
Then I applied silver spray paint.
When the paint dried I bought some sports grip.
And I started wrapping it around the 3 handles.
And I'm done!
I was so happy to finally finish this project. The wood version is durable, has a good weight to it and came out so much better than the foam one would have come out.