Nice clamping jig, Erin.
:shush: It's top secret... I haven't patented the jig yet. Just trying to give Mr. Wheeler a run for his money. :9:
Erin
Sorry to hear of your Families misfortune. Our thoughts and prayers are with you.
God Bless
Mike
Thanks Mike... we seem to be doing OK. We appreciate the prayers.
i'm no expert, but i pretty much think this WIP falls under Tutorial!! its pretty simple, detailed, and AWESOME
I'm going to stick with WIP. In my opinion,
tutorials are done by folk who know what they are doing and have some level of confidence in how the project will turn out. For the most part, I have neither... I'm just inviting y'all along for the journey: good, bad and ugly.
That being said, I have finished the knife and am EXTREMELY happy with how it turned out.

unk: The handle is the most intricate I have ever attempted, but ended up looking decent... and the blade, I'd have to say it's my best polish ever. In fact, I feel that this knife is my nicest to date. Unfortunately, I can't take any photos until I finish the "saya"/scabbard. :001_tt2:
I started the saya yesterday. It is taking forever. In this first photo, I have traced the blade onto the walnut halves. I originally planned to use a poplar lining surrounded by walnut, but this saya is just too small to make that work out.
In this photo I have just started carving the blade shape with chisels. I start by taking the majority of the material out "across the grain" as shown, but do final shaving and clean up with the grain. I also carve a bit of extra room where the blade edge will be to minimize contact with cutting edge and the wood.
This process is VERY time consuming and involves dozens of "test-fits" with the actual knife. It is important that the blade slide in easily, but that there is a snug fit at the habaki so the knife won't fall out.
Before gluing the pieces together, I copy the blade shape to the outside face of one of the blocks. I also draw in the proposed profile of the saya. This will help me avoid removing too much material. This step is very important.
Here is my high-tech saya clamping jig. :22:
I'm using Titebond III wood glue, and make sure I minimize the "squeeze-out" into the interior of the saya.
This morning I ran the glued block through my band saw to get a rough profile.
I then cleaned up the profile on my belt grinder.
Next I used the band saw and belt grinder to create a taper to the saya. Then, while the pieces are square, I drilled and epoxied some decorative mosaic pins near the top. This is what the saya looks like now.
That's all I've got for today. We're getting close. :s11798: