Aaaand it's done! As a brief rundown, it's 700 layer damascus blade, the blade, guard, and pommel were all rough forged to shape before grinding the rest of the way. Handle is cocobolo like the original prop, but I just could not figure a way of replicating the vine inlay as it was done on the prop for The Hobbit. If I remember rightly they didn't do that on the LOTR prop either, it was a vinyl sticker. So instead I have a fluted handle with a twisted sterling silver wire inlay. I did peen the pommel on, so that sucker is not coming off.
I just remembered that you asked this, so here's a couple of pics.
This is before peening. I've chamfered the edge of the tang hole so that I can grind the pommel smooth but it will still have some solid purchase. I heated it up to just below a dull red colour and used a rounding hammer to squish it down. I would have liked to get it a little hotter but I just have a regular propane torch and it just wasn't hot enough.
And this is what it looks like finished. It could probably be a little neater, but it works. I guess I could always weld it to fill those small gaps.
Hey thanks guys. I think my next one is going to be either Aragorn's ranger sword or Glamdring. First I need to do some regular work though and make some money. I love projects like this but they don't bring in the dough.