I started with a pine board. It was a composite board, with pieces glued together the way a cutting boars is assembled. I couldn't find a solid plank that was 6 feet long. I drew the outline (handle to blade tip) and cut it out with an electric saw. Then I sanded the CRAP out of it. I used a rasp, a metal file and sandpaper to bevel the blade edge. I used PVC parts and a length of PVC tube to make the handle. The tang barely fit into the pipe and I had to sand it down a few times before it fit. Its so tight I didn't even need glue or anything. I used drywall spackle (not ideal but I already had it) to fill in the ends of the pipe so it looked smooth and solid. I sunk a length of chain into the end of the handle with glue. I bought ribbon and wrapped the handle, then painted the blade. In hindsight, I wish I had NOT used the pvc for the handle and had figured out how to make it round another way. The handle is larger than my previous shikai, and its kind of a pain to carry around. Most of that is because the weight of the blade, but with it being wood I don't have to worry about it getting really banged up.