Took some really good screen grabs and found a couple of excellent studio images (including one truly insane glamour shot). Did some measurements of Jensen Ackles based on a photo of us standing together - as well as various promo images - and my guestimates put the blade at eighteen inches (which, honestly, might be a little conservative - but tests of templates made it seem crazy to go any longer). After tracing the shape onto paper, wooden "blanks" were cut this morning. I'm going to try to start putting this together over the next two weeks, as Timothy Omundson (Carlton "Lassie" Lassiter from Psych and CAIN from SPN) is at a nerd con in Chicago, and it would be super cool to have him sign one (I've got a Colt signed by Ackles, a Taurus signed by Jared Padelecki, and an angel blade signed by Misha Collins).
If it looks good when its done, I'm sure I can find someone to cast it and do some replicas. We'll see. I'm not so confident in my abilities at speed.