Okay here is the guide that I promised. It'll be in two posts or parts. Couple things to note:
1) I should have used my camera instead of my phone.
2) I'm not trained in any way in woodwork. I'll try not to use terms like "pointy end" but I won't make any promises! I welcome any hints and tricks as to how to improve my woodworking skills.
3) This is meant as a starting point for others. I hope it gives you some confidence and others try it for yourself. True happiness comes in doing.
So here goes.
The first step is to get some wood. I had visions of splitting dark ebony and rich bubinga and putting them together so as not to see the seam but..
I got a two foot section of 1/4 thick, 4 in wide red oak (bad decision in retrospect as it is too hard for me to work with easily). Took it home and got my tools ready.
I also used a circular saw and a belt sander but they aren't shown.
I cut it in half and then squared up the two so they were the same length. I fit them together this way and that until I found the flatest fit and marked the sides which would go together.
Next was marking one side for the shape of the blade. I marked one side, then moved the knife about 2 mm down to make sure that there is enough room for the knife. I don't know if this is good or not, but I didn't want the fit to be really snug. You can see in the picture the line is a little off the spine.
First I punched the outline using a chisel and then went at it with a straight bit on the router, hollowing out the cavity. For this one I kept it all at the same depth, just clearing the spine. I used a wood knife "Thingy" to clean up the tip. I checked from time to time to make sure I was on the right track, eventually putting the other piece on and checking the knife's fit.
Little light sanding, little wood glue and then clamps. Then a beer. (I mean water for those offended by such). Made by Leinenkugel in honor of Mark.
Man this is more work than the project... I need another "water". Part two coming after the break!