Recently I finally ran into a more or less suitable blade for this project: a Rifleman blade sold by Crazy Crow (it was discussed on this thread: http://myArmoury.com/talk/viewtopic.php?t=11707&start=66 ). Not quite what I wanted (a little short at 11", should have been several inches longer) but close and very cheap. So I decided to do this project as a learning experience - I have never before done a Messer style hilt and wanted to try.
I had to put a lot of effort into modifying/fixing the tang (discussed in detail on the above thread) but in the end it came out pretty well. The blade is approximately 3/16" thick, and with some "reverse distal taper"! I mean it is 11/64" at the guard and 13/64" at the start of false edge. Cross section is rather thick, and I sharpened it with a convex edge to preserve strength (since it isn't very hard, I would say like machetes typically are). So it is a front heavy beast for its length, which is actually good for this project - has a feel of a decent chopper it is supposed to be. Kind of compensates for relative shortness.
The guard, nagel, buttcap, and scabbard fittings are all 1018 mild steel satin finished to 220 grit, blade 400 grit.
I imagine this level of finish (rather than mirror polish) would be a reasonable expectation for a XVIc peasant's weapon.
Handle scales are curly maple, finished with tung oil, fixed with 1/4" brass tube pins.
Overall handle is 4 3/4" long, 3/4" thick.
Scabbard is thick leather, hardened in hot beeswax. This treatment made it contract by over 1/4" in length, so I had to add a rather awkward extension covered by steel collar (wasn't planning on it originally). The blade to scabbard fit turned out very tight (because of the blade's reverse distal taper which I didn't think of until too late), takes something like 20 lb of pull. So leather work was only a partial success. But I like how the chape turned out, this is the first time I managed to fabricate a chape with a finial at the end rather than just a flat bottom.
I am attaching some pictures here, but more are available in an album at: https://public.fotki.com/aindman/bruegel-inspired-pe/
Any comments / critique?
Alex.

Peasant Dance painting detail [ Download ]

Messer and scabbard [ Download ]

Buttcap view [ Download ]