Making a San Mai Tanto - Chapter #4: The Wooden Sheath (31 pictures here)

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Mar 26, 2004
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Making a San Mai Tanto - Chapter #4: The Wooden Sheath

Here's the previous installment:
http://www.bladeforums.com/forums/showthread.php?t=351296


Two pieces of African Padauk (9" x 2 1/2" x 1/2") to start working on the handle.

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Marking the contour of the blade with a pen.

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Marked pieces.

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Milling the space for the blade. I don't have a milling machine so I move the piece myself. The depth of the milling is half of the blade width for each wooden side.

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Finishing with a file.

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Checking the exact fitting.

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Making some 2mm holes (1/4" depth) to later put some wooden pegs there to keep the halves together.

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Putting the wooden pegs.

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One half already done, ready to be glued to the other.

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Pressing both pieces together for a perfect match for the glueing.

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Sheath already shaped after grinding, sanded and ready for the laquering process.

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Using masking tape to make some decorative patterns.

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Applying black lacquer with an aerograph.

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After removing the masking tape, the first lacquering stage is completed.

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For the second lacquering stage instead of masking tape, I use a plastic net from a big bag of potatoes.

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Second lacquering stage completed.

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I apply 6 layers of transparent poliuretanic lacquer. After each layer I let it dry before applying the second one. Every two layers, I sand it with a 400 grit sandpaper.

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After letting it dry for two more days, I sand it with a 600 grit sandpaper and water.

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Polishing it with an coarse lacquer polishing paste (same as you'd use on a car) with a cotton cloth til it gets shiny and glossy.

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Polishing it again with a thinner lacquer polishing paste, again with a cotton cloth, this time in circles, until the sheath shines even more.

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very cool, i love seeing your pictorials, they help me get a grasp on how things happen that words can't do justice, awesome sheath
 
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