Interesting to see the difference between the two felts. Did you do the entire bevel with the felt or did you use a platen first? I just recently started using felt and I'm still experimenting with it.Basswood core, other woods on the outside panels works great. Most of the Japanese saya are wood similar to Poplar on the outside.
I use Basswood in the thickness for the thickest part of the blade, trace blade and cut out. Glue outer panels on (Titebond original, others are said to lead to rust due to off gassing?), shape and sand.
Profiling out 2 Nitro V blades for this, but I found an already hardened AEB-L blade I may use instead.
Been playing with grinding methods and different hardness of felt.
.140" S30V with S2-32 Hard Felt:
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.140" S30V with F3 felt (same knife, different handle):
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Tojiro ITK Shirogami 240mm Kiritsuke gyuto completely reground (No more Kurouchi finish, thinned way down to a laser):
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Cool alloy banding and stuff on the Tojiro, too
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I was planning to do the saya from two pieces and chisel out a recess for the blade in one half, then glue on the second half. Is there a problem with Titebond II, or are you referring to non-PVA glues such as polyurethane?