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:
Step 2: Cut out the inside of the tracing for the blade to slip into:
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.
Glue, clamp and set aside until the glue is cured:
Ready to rough shape the profile, cut the handle opening:
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.
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!