I think it was Mike I was talking to about plastic machete's. Anywho, that gave me the idea. It cost £3.99 inc P&P from fleabay and comes with an all shiny silver 'blade', unlike the photo in the listing. That would never do so I taped off the 'edge' and sprayed the blade black. I then removed the tape to see how it looked, decided it looked far too pristine and distressed it. I then sprayed it with Clear Coat, like a pillock forgetting what this would do to the shiny edge - I then had to take the varnish off the edge with thinners, which has taken a bit of silver with it ho hum...
I also wrapped the hilt in the trad Japanese manner, using an extra long bootlace I had knocking about. Not too bad looking I think. Then I needed a sheath. It's surprisingly difficult to find them for reasonable money, so I made my own. I started with two sparkling water bottles and shaped them around a couple of bits of wood by pouring boiling water onto them:
I then sewed a DPM cover for it and glued it in place:
The webbing straps are stitched to the cover and form a belt loop with velcro. It's designed to be carried on a shoulder strap, as above, or looped over the inside of a PLCE belt like this: