I'd use a good coal instead of wood unless you prefered the wood.
I'd either make the blade out of spring steel and drawn out to the right thickness or sandwich a soft steel core with a harder edge which requires more work.
I believe in a full as wide as possible tang, but shaped as the real one would have been and not as the reproductions are.
The hilt would be of brass, some etchings or markings I can do and those more intricate would have to be subbed out to some one that is better skilled.
For a time I'd have to leave the wood and wire wrapping of the grip to you due to the work schedule around here.
Heres a link to another blade maker in Scotland, and frankly his prices are better then mine, he can keep his cost down by using stock steels bought over the counter
If I do it in this fashion I can pretty well match him on most items dollar for his pound.
The castle keepHope this helps but please feel free to ask for more details, I'll help in what ever way I can.