It looks like it weighs a ton but actually only weighs about 2.5lbs.
To "forge" it, I first built the head out of cardboard (using the power of geometry). Then I cut a piece of wood dowel for the handle, making sure that when inserted it would run through the whole head for stability.
Then I used super sculpty to cover the head and sculpt all the aged metal detail. To give the whole thing weight and strength, I filled the head with expandable foam that air hardens to a wood-like density. I wrapped the handle in leather and used the tip of a hot iron to burn random groove marks into it to make the wrapped handle look worn.
Last, I painted the head black; dry brushed it with flat aluminum paint, added some black wash and sealed it with a few coats of dull coat spray. The end result is Uru that looks like it has been through countless battles with rock trolls, frost giants and the occasional elemental demon.
I seriously can't put this thing down. It looks bigger and meaner than what is on the market but is light enough to swing around (even by the thong).