Small knife

Your script says “hero cuts the rope with a small knife”. So, you need a small knife. Well, one thing you can do is to craft one from a piece of aluminum bar.

mark it

mark it

Mark your pattern out on a piece of aluminum flat stock. This is 1/8″ thick and about 1″ wide. Something like this probably costs $10 at the local hardware store.

Cut it out with your hand tools.

cut it out

cut it out

hammer the blade

hammer the blade

Hammer the blade to add some texture and to thin the edge.

hammered

hammered

When you hammer it, the metal will bend away from the hammer marks.

dull

dull

Use some sandpaper to ensure the blade edge is dull so no one is hurt.

handle

handle

Cut two pieces of thin wood for the handle.

two part epoxy for the wood

two part epoxy for the wood

This is the type of epoxy I use. It is two part, and can be found at the local hardware store.

paint

paint

While the handle is still rough wood, spray the blade black.

shape the handle

shape the handle

Shape the handle.

rough knife

rough knife

The rough knife is basically done.

sand

sand

Sand the handle.

stain

stain

Stain the handle.

Looking good

Looking good

The handle is stained, and the blade sanded a little to allow some of the silver looking aluminum to show through.

sawdust again

sawdust again

Distress it again with some sawdust.

finished

finished

There is your finished blade, ready for the hero to cut the rope.

hero knife

hero knife

So, a knife like this would cost you a few dollars in metal and wood and glue. It takes a day or so of labor. The aluminum is really light weight. This can be good and bad. Your actor may have do some acting to make it seem like a real heavy knife. This technique can be used to make a sword as well. It takes smaller tools than real steel. Aluminum is easier to form and shape for people with fewer tools.

Go ahead, make a mess, make a knife, have some fun.

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