![]() Remember, (as Norm Abrams would say) "there is no more important shop safety rule than to wear your safety glasses". Once you are happy with the shape and design, cut it out with a jigsaw, band saw or scroll saw. My blade ended up at 3-1/2 - 4 feet long, but you can really do any size or design you want, just make sure to leave the blade’s tang long enough so it can be attached to the shaft. For me, this was one of the more difficult parts of the project, but maybe that's because I'm a perfectionist. You can see from the photos, it took me a few tries before I was finally happy with the design. Use a pencil to draw the blade shape onto a scrap piece of 1/2” plywood.
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