Backsword construction
My friends at Lonin’s BWAHAHAHA group helped out our club by supplying two Gus Trim i-beam blades and a pair of substantially pre-built baskethilt kits. My process, depicted below in pictures, was to assemble the baskets, design and build a hardened leather cover for the basket, and create a suitable handle and final assembly.
This is the process for the first one; I expect the second one to be slightly more presentable-looking. The hardened leather turned out very well, though I have yet to test it against significant impacts.
Contact me if questions about any of this.