JR, go find an old crosscut saw. Cut your blade blank on an anvil with a hammer and chisel. Shape dip, shape dip and have a blast. Do NOT overheat it. It will retain an edge like you won't believe. Your problem will be when you try and drill the holes in it for your rivets. Have used this method for years. I was taught when very young by my father who was a machinist millwright. We had the forge and all of the other things needed. We case hardened with cyanide. Don't use that route, cause I don't need to be hearing that you croaked yourself from fumes. If you plan on case hardening, an oil dip will work for you. I have my doubts that you have the furnace to do the hardening with kasenit. I want to see pics when you get this done.