For the Bat’leth, I started with a few difference references to get the scale and shape correct.
The first draft looked like this:
I showed it off to a fan form for them to tear it apart. They exceeded my expectations, and directed me to an episode of Deep Space 9:
http://www.startrek.com/watch_episode/T_FQA19c6LaI (relevant clip at 22:39)
DAX: Computer. I want a Klingon bat’leth, tip to tip one hundred and sixteen centimetres, weight five point three kilos with an exterior handgripping diameter of five centimetres. Blades composite baakonite.
KOLOTH: Ah, a warrior’s configuration. Now what are you going to do with it?
I went back the sketch, increased the size and thickness, and changed the shape to get the weight spot on.
Then I cut it on the CNC plasma cutter:
Here’s the product so far:
Next up, I’ll want to invent a grinder attachment to make these long edges much safer to grind.