coregeek
Active Member
I recently completed a scratch build of Tauriel's Daggers from The Hobbit films. Thought I'd share the complete build process.
This is a comprehensive build covering the prop master build, molding/casting, and final finishing.
I have 50+ photos so I'll post in sections.
I started with a piece of scrap 5/8" thick MDF that I sawed down to 3/8" thick.
Transferred reference to MDF.
![tdcoregeek-1.jpg tdcoregeek-1.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235090-d80f89095b2c2a699144d819e803d755.jpg)
Drilled out spots to make cutouts with scroll saw.
![tdcoregeek-2.jpg tdcoregeek-2.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235091-ac3e888aacd5bc54659f6ae7c766e324.jpg)
Cutouts made. I decided not to cutout the two small hole on the blade. I didn't want to deal with them during the molding process.
I also decided to cut them in one string so I wouldn't have to fiddle with removing the scroll saw blade a bunch.
![tdcoregeek-3.jpg tdcoregeek-3.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235092-340c95dd01c4360fbae2977dea212414.jpg)
Starting the bevel of the blade. I freehanded this with my bench belt sander.
![tdcoregeek-4.jpg tdcoregeek-4.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235093-9bc609ce7925372435c3bababb923ab7.jpg)
Cleaned up the transition of the blade to handle by hand cutting and sanding.
![tdcoregeek-5.jpg tdcoregeek-5.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235094-34a1e7f69531dd2d368906e81175e819.jpg)
Still rough cuts at this point.
![tdcoregeek-6.jpg tdcoregeek-6.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235095-f9f2a4c1916ed06a05ad2442cabbdf51.jpg)
Shaping the blunt edge top.
![tdcoregeek-8.jpg tdcoregeek-8.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235109-45173d87cae885616feae5be3f12cb84.jpg)
Overall progress.
![tdcoregeek-10.jpg tdcoregeek-10.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235110-b3445b7df07228fbf2d176dc08268e19.jpg)
Built up the handle thickness by gluing MDF slats on each side.
![tdcoregeek-12.jpg tdcoregeek-12.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235098-9f327553ed2293e60f52735a2c5f2dd6.jpg)
Shaped the handle with combination of belt sander and hand sanding. The handle had several angles that made it a bit of a challenge to get right.
![tdcoregeek-15.jpg tdcoregeek-15.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235107-d23218524b70c401cd54647f758afca0.jpg)
That's it for the MDF.
Next up adding all the detailing.
This is a comprehensive build covering the prop master build, molding/casting, and final finishing.
I have 50+ photos so I'll post in sections.
I started with a piece of scrap 5/8" thick MDF that I sawed down to 3/8" thick.
Transferred reference to MDF.
![tdcoregeek-1.jpg tdcoregeek-1.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235090-d80f89095b2c2a699144d819e803d755.jpg)
Drilled out spots to make cutouts with scroll saw.
![tdcoregeek-2.jpg tdcoregeek-2.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235091-ac3e888aacd5bc54659f6ae7c766e324.jpg)
Cutouts made. I decided not to cutout the two small hole on the blade. I didn't want to deal with them during the molding process.
I also decided to cut them in one string so I wouldn't have to fiddle with removing the scroll saw blade a bunch.
![tdcoregeek-3.jpg tdcoregeek-3.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235092-340c95dd01c4360fbae2977dea212414.jpg)
Starting the bevel of the blade. I freehanded this with my bench belt sander.
![tdcoregeek-4.jpg tdcoregeek-4.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235093-9bc609ce7925372435c3bababb923ab7.jpg)
Cleaned up the transition of the blade to handle by hand cutting and sanding.
![tdcoregeek-5.jpg tdcoregeek-5.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235094-34a1e7f69531dd2d368906e81175e819.jpg)
Still rough cuts at this point.
![tdcoregeek-6.jpg tdcoregeek-6.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235095-f9f2a4c1916ed06a05ad2442cabbdf51.jpg)
Shaping the blunt edge top.
![tdcoregeek-7.jpg tdcoregeek-7.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235096-ebb55149bea3a61efb6c5ffbd0d818f3.jpg)
![tdcoregeek-8.jpg tdcoregeek-8.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235109-45173d87cae885616feae5be3f12cb84.jpg)
Overall progress.
![tdcoregeek-10.jpg tdcoregeek-10.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235110-b3445b7df07228fbf2d176dc08268e19.jpg)
Built up the handle thickness by gluing MDF slats on each side.
![tdcoregeek-11.jpg tdcoregeek-11.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235097-87f94b62dde43827f40c3339bbc2f19e.jpg)
![tdcoregeek-12.jpg tdcoregeek-12.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235098-9f327553ed2293e60f52735a2c5f2dd6.jpg)
Shaped the handle with combination of belt sander and hand sanding. The handle had several angles that made it a bit of a challenge to get right.
![tdcoregeek-14.jpg tdcoregeek-14.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235099-b11b47a4e23afadba2215e326cd86c2e.jpg)
![tdcoregeek-15.jpg tdcoregeek-15.jpg](https://therpf-f28a.kxcdn.com/forums/data/attachments/235/235107-d23218524b70c401cd54647f758afca0.jpg)
That's it for the MDF.
Next up adding all the detailing.
Last edited: