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Saya WIP

Thu Mar 14, 2013 5:51 pm

Well, I worked on 2 Saya's today, so I figured I would do a quick WIP!

Step One: Trace blade/handle onto the spacer piece. I size the spacer to fit pretty close to the spine thickness in front of the handle:
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Step 2: Cut out the inside of the tracing for the blade to slip into:
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As you can see, I also trace the cut out for the blade on the outside of the Saya pieces so I don't cut too far and cut thru the spacer when shaping. I also label the edge and spine side of the pieces (helps keep them straight when gluing)

Test fit before gluing it up, I also mark where the cut out will be for the handle.
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Glue, clamp and set aside until the glue is cured:
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Ready to rough shape the profile, cut the handle opening:
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Profiled out, and the blades fitted to the spacer. There is usually some cleanup to the inside of the saya's so the knives slip in tightly.
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Top one is a 270mm Konosuke Honyaki Gyuto with a Wenge Saya, bottom is a 270mm Moritaka Yanagiba (double sided) with a Bolivian Rosewood saya.

Next up, I will drill the pin hole, chamfer the hole and sand the sides down nice and smooth, then a few coats of finish!

Re: Saya WIP

Thu Mar 14, 2013 8:54 pm

Nice work. Both look great.

Re: Saya WIP

Thu Mar 14, 2013 10:58 pm

Looks awsome Tim!!

Chris

Re: Saya WIP

Fri Mar 15, 2013 12:59 am

My kono loves his new home Tim :) You're a animal. lol

Re: Saya WIP

Fri Mar 15, 2013 2:52 am

I think you should be careful too make sure you have plenty of clamps on your sayas as you glue them up. We want them nice and tight all the way around. :geek:

Re: Saya WIP

Fri Mar 15, 2013 4:08 am

LOL. I went to Harbor Freight and bought like 45 of those little clamps. They work well for Saya's, handles, etc. $.99 each clamp I think. I have 2 other sizes in the same style, but find myself using the smaller ones more and more. I usually use 4 or 5 per side for a 210-240mm, but these were 270mm's, so I went crazy with the clamps!

Re: Saya WIP

Fri Mar 15, 2013 5:28 am

Tim, those look great. Can you post a picture of the blade sitting out of the saya on top of it to give an idea of the size?

Re: Saya WIP

Sat Mar 16, 2013 12:11 am

Yup! They are a little big still, so I need to drill the pin hole and then bring the profile down to the final size and then hand sand the sheath; I usually go up to around 600 grit or so.

Re: Saya WIP

Sun Mar 17, 2013 8:27 pm

Got these finished up today!

Drilled the pin hole and chamfered it, sanded the saya's up to 600 grit, broke the edges/corners and then did a coat of Tru Oil and a few of Tung Oil today.

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Blades on top of the Saya's:
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Re: Saya WIP

Sun Mar 17, 2013 8:50 pm

Very nice. Thanks for the shot of them out. I was having a hard time picturing the amount of spacer being covered by the outer panels.

They look great!
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