The
following series of photos shows some of the steps involved in building a Japanese
style knife and sword. Many of the early stage photos show the construction of
a shira-saya for a Jason Arnold (Black Sheep Forge) aikuchi, as these are similar
to the steps required to make the larger swords.
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When carving out the saya (scabbard), the goal is to have wood-to-metal contact
the full length of the blade. Poplar is similar to traditional Japanese magnolia,
has a straight grain, soft texture, and no acids to attack the blade.
Habaki
rough silver castings, filed and fitted to blade. The habaki is required prior
to finishing the saya, as it holds the blade tight in the sheath. I experimented
with two different styles, but the simpler one seemed more complimentary.
For
weapons that were carried, grips were fitted with rayskin and silk braid-wrapping,
plain or decorated guards, spacers to provide a tight fit, and grip collars and
butt caps to hold the grip halves together. Scabbards were lacquered and often
decorated as well.
The
metal furniture often was the product of master craftsmen who specialized
in creating the miniature masterpieces — carving, engraving, inlaying,
and plating whole battle scenes on a metal canvas 3'' in diameter.
In
the following photos, copper pieces were filed rough then fired and quenched to
create a multi-colored finish.
