i just finished rebuilding this one, a Willow Leaf Dao, so named as the blade is thinner than the wide Oxtail Dao. I'm getting to prefer the willow leaf, even tho the oxtail seems to be more common. I find the wide blade of the oxtail to create a more cumbersome weapon.
In the past, I rebuilt hilts by bronze casting, which is a lengthy multi-step process. I've liked the results, but the amount of time and work that goes into it can encourage me to avoid it. This time I took a different approach and cut the pieces out of steel bar that I got from Lowes. I actually cut the tang off the original blade and reshaped the bottom 6-7 inches of blade into a new tang. I then cut the guard from 1/4 inch steel plate, and the two pieces of the pommel from 3/8 inch steel plate. The grip is strips of hickory. I shaped it all and fit it to the tang with heavy grade two-part epoxy and 1/4 inch steel pins.
This is far from perfect, but is completely serviceable and I'm happy with the results. I had a few dead-ends and had to redo some parts a couple times, and I learned a lot in the process. It still took about 1/4 to 1/3 the time to build as the bronze casting would have taken.
I did do some training with this sword before I rebuilt it, and the blade was longer than I liked and poorly balanced. I'm much happier with it now, having shortened it and shifted the balance on it a bit.