Made in tandem with Pyramid Head's helmet, the Great Knife was a large but straightforward build. The blade was cut out of a single poplar board using a jigsaw and the edge shaped with a belt sander. The teeth on the spine were each cut individually using a scroll saw then glued into place. The handle was cut from a pine block on a bandsaw, then shaped using a belt sander and hand sanding. Finally the pommel and guard were cut and shaped from polystyrene blocks which were then reinforced with fiber glass shells. Once construction of the whole was complete the handle was masked off and the entire piece painted with a metallic lacquer. After the paint had been buffed to a sheen, the handle was then colored with wood stain, sealed, and a wrap applied using one continuous strip of leather. The first step of weathering was to add actual rust using a method combining iron powder and an oxidizer on various parts on the blade. Next multiple washes of acrylic paint were added and the entire piece was clear coated to protect the paint and prevent the rust from further oxidizing. Finally the fake blood was brushed and spattered on using a paint formulated to have the color and sheen of fresh blood.