I was working on making a Colonial Marines knife from Aliens. I found some pictures of the blade in its blank form. The tang looks very similar to the tang of a file. I heated a file in a 400 degree oven for a couple of hours. Then ground it to shape.

Then a few days ago I found that Props3DPro had modeled the knife correctly. It was only uploaded as a .stl, but I was able to convert it to a solid model in Fusion 360. At least good enough to make the internal changes that I needed. I added a cut-out for the tang of the file then combined the parts and split it for printing in halves.

The grip was glued together with 2 pieces of 3/32" tig rod in the slots to reinforce it. Then the blade was glued in.

The Fusion 360 file is included.

Category: Props