It probably seems like I forgot about this prop, but I haven't. Actually, it turned into a complete nightmare. First, if you remember, I laid out the pattern on cardboard. Then, I cut it out.
Now there's a trick to it. To use foamboard like this, I had to layer it. You can see it in the picture above. The other problem was that this has very slight angles on the edges for the blade, which is quite thin, so I couldn't build on it. After some pondering, I carefully cut 1/8th of an inch from the edge into the paper and removed the first layer, then sanded the foam beneath to give me a sloped edge!
Now, all of this was very rough, not smooth, and clearly doesn't have the beveled edges the dagger should. So, that process began with an old friend of mine - Sculpy Clay!