As you can read on this page I previous made two saya out of interest and eventually out of necessity. It gives great joy and satisfaction to make and eventually train with a custom made saya. Not only is the fitting perfect but you can really make the saya personal.
Now I was asked to make a custom saya for my sensei.
Here you will be able to see the whole process.
The first thing was to cut the available piece of magnolia wood into two equal sized parts. This was done with the help of my friend Denys Goossens who is a talented wood worker and carpenter.
Than the lines where made as to see where the blade will be positioned.
With a knife I create the sides of where the blade will rest on in the wood.
The side where the sharp edge of the blade will be is less than 2 millimeter
After chiseling both pieces of wood in such a way that the blade fits in half the thickness of the blade it is time to glue them together. I use the rabbit glue as to ensure nothing will be hsed that might effect the blade.
A little update: today I found some time to sandpaper the saya more to its traditional shape.
Today I found some time to give the saya the last sandpaper and start on the kojiri and kurigata. Both again made from buffel horn. It’s both a nice and nasty job. It is beauty that you create but it smells terrible and gives an enormous amount of (smelly) dust.
Today I had a visit from a client who ordered a saya for one of his shinken. He also brought a beauty of a shinken that was made in Japan. A wonderful opportunity to see the master’s work at hand. What a difference. With yhat in mind I continued with the kojiri and the kurigata.
Time to make some little colour samples:
After several layers of primer and sandpaper again it’s time to start creating some colour. The indicated wish is dark Japanese red. But this might change…let’s see..