Plunge router for two-piece handles/sayas?

L

Leon Husock

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Jul 17, 2019
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Has anyone ever tried this? I can never quite get the hang of a chisel and I have a two piece sword handle to make, so I was wondering if I could use a plunge router and just route out the shape of the tang.
 
What kind of wood are you using?
I just made 5 saya. I have a good set of sharp chisels, but some types of wood come off in nice smooth cuts, while some like to chip and splinter.
If you want the saya to really follow the shape of the blade, then you need to shape the two pieces. If not, you can make it from 3 pieces and just make a cutout of your profile for the middle piece. That is by far the fastest and easiest.

ETA: sorry, I just noticed that you are making a two piece handle. I would say, yes, you could try a router or mill
 
I'm interested in this for sayas too, but yeah my immediate concern is the two-piece handle. Thanks, though! I'll keep that in mind.
 
There is a vid of Alex Steele using a router for a two piece sword handle on YT. After cursing about chiseling the another handle for hours.
 
I use a laminate trimmer router and a mortising bit. It is plenty strong enough. Although, Dremel makes router attachments, etc. , and then you’d have one of those for other things too.
 
I use an angle grinder. A 60 grit flap carves out the interior very easily. You start in the middle and work your way to the edges sneaking up on the line. Add a little depth and check repeat.
 
I have a Steweart-MacDonald mini-router that runs off my flexshaft. I have also used a small plunge router.
 
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