This is how I made a dagger out of aluminum-which happens to be one of my favorite projects. It took a bit of work, but the end result is beautiful. It even starred in a movie already!
The first thing I did was find a picture of a dagger. After browsing the internet for a couple hours, I eventually went with one that I liked the look of.
I then printed it, and cut it out with a exacto-knife. Unfortunately my exacto knife is quite dull, so I have to push pretty hard.
After tracing it onto some wood, I proceeded to cut out the shape with a bandsaw, and then shave down the wood into a dagger shape using hand tools and my trusty dremmel.
I then created the mold that I was going to use to pour the aluminum in.
After clamping the two halves back together, I then melted some aluminum and poured it in. Here is the initial result after cutting off excess aluminium.
After a ton of sanding and polishing, I eventually ended up with this.
I then added some leather to the grip, and I embedded some jewels in the crossguard.
I plan on making another one at some point. Well, maybe when I get more aluminum...