A fake butcher knife is used for many different activities such as a prop for a homemade movie, as part of a Halloween costume, or even a prop for a school play. A costume prop butcher knife is harmless because the materials you make it out of are risk-free and non-toxic. If you are in a rush you can make a fake butcher knife out of cardboard and glue. However, if you want to make a realistic prop that will last for a few days it is best to purchase durable materials like wood and hard plastic from your local hardware store.
Use the black Sharpie marker to trace the handle of the butcher knife on the wooden board. Cut out the handle shape with your multipurpose saw. Use the sandpaper to smooth down the new handle.
Trace the blade of the butcher knife on the sheet of hard plastic using the black sharpie marker; cut out the blade with the multipurpose saw. Use a sheet of sandpaper to smooth the edges of the plastic blade; lightly sand the excess or jagged plastic with the coarse side until the plastic blade is smooth. The abrasive sandpaper should do the trick since the plastic is not that thick.
Take a small piece of excess plastic, no bigger than the flat part of the head of the handle and slit it in the middle; do not slit the piece of plastic all the way down the middle because you will cut it in two pieces. Insert a small portion of the wide part of the plastic blade through the slit; fold it upward and glue it together. You should now have a blade that can stand up vertically.
Glue the plastic blade handle onto the flat part of the head of the handle; allow the glue to set for two hours to ensure that the two pieces will not come apart. Spray paint the wooden handle black and the plastic blade silver; the spray paint should dry in an hour.
Children under the age of twelve should not be allowed to do this project without adult supervision. Small children can hurt themselves with the real butcher knife and the handsaw. They may also be tempted to taste the glue.