Trace the blade template on a piece suitable steel stock: I used 1070 high carbon steel 5mm thick since is easy to heat treat like most high carbon steel.

Cut the knife black with watever you have aveiable. I have a metal cutting bandsaw so of course I use that but any angle grinder with a cut off wheel or even an old hacksaw can do the job.

Drill some hole in the tang to reduece the weight and most importantly to give something at the aluminum to hold to later on.

You can find the template attatched here for free, I made it on cad following reference image found on Google.