Stacked leather for a sword handle?

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Aug 6, 2007
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Is there any reason I have never seen this? I have a sword I am trying a few different things on and I was thinking of trying stacked leather for the handle. There's enough tutorials around to know HOW to do it, just wondering if anyone has ever done it.

Will there be a large weight difference weight wise between leather and wood?
 
I've never seen it done either Sam, but that does'nt mean it would'nt work or look nice. You could always use a little larger pommel to make up any weight differences between wood and leather.
 
The tang would have to be almost full size since there's no added strength from the leather washers (at least to my way of thinking.)

Not sure what style of sword but I've seen pictures of very old katanas and tantos that were leather wrapped over wood, pretty sure a lot of the older European swords were also leather wrapped over wood. These weren't wrapped like you would think but more like an ace bandage wrap.
 
the mental image of a stacked lether sword kinda makes me think of an exagerated Kabar, Sam... which now that I think of it, it does sound kinda cool!

Jason
 
My first thought was that the handle might not be strong enough for a sword. Wood would give the tang some support, not sure that leather would help much. This may be why we haven't seen it before. That being said, I think it would look really cool.
 
Well what about a smaller than normal wooden handle then just make large washers to go over that handle to give the same look? I just don't think that a small tang will handle the stresses generated. A Kabar used to chop doesn't generate the same amount of energy.

Course if it's just for you then might as well try it, you could always rework the handle provided nothing breaks :p
 
I like that idea Will, but I'm sure glad I wouldn't have to cut out the leather washers! :D It's a pain in the butt just doing a knife handle...much less cutting out for a foot-long wood-supported tang. Yikes! :D
 
For a sword handle you want something rigid that puts the tang in tension between the pommel and the blade shoulders or you run the risk of breaking the tang in heavy use.

-Page
 
I like that idea Will, but I'm sure glad I wouldn't have to cut out the leather washers! :D It's a pain in the butt just doing a knife handle...much less cutting out for a foot-long wood-supported tang. Yikes! :D

Why? we're knifemakers right? so make a tool to punch out the holes. I'm guessing a piece of wood shaped a little under the desired size of the hole, take a thin piece of metal, run it around like a ferrule, secure it with some pins or scres, put a small bevel on it and use it as a punch? Get a piece of metal pipe that circumference, heat it and beat it to the outline, bevel the edge, use as a punch.

Course all this is easy for me to say since I have NO plans on doing something similar :p
 
Sam,
Make a stacked leather mandrel. I'll try and find mine for photos tonight, but will describe it for now. This is how I make most stacked leather handles, and will work for any knife.

Make a replica tang in mild steel with a good shoulder for the guard It does not need to be fancy, just a pretty close match for the sword tang in measurements. Leave a 2-3" extension as would take the pommel nut, and thread it for a nut, say 1/4-20. Leave enough "blade" section to hold onto while assembling the handle. About 6" is fine.Make a simple guard like a big washer with a slot. Make a similar round piece that fits the top of the tang where the handle will end.

Cut the leather into rectangles or squares (no need to make rounded) , and slot them so they fit the tang. Slide them on the actual sword tang as you cut the, to make sure they fit.The stack should be about 3/4" longer than the desired handle length.The fit does not need to be all that precise. The hole will be filled in the next steps.If you are making a punch, I would make three sizes, to fit the bottom, middle, and top of the tang.You can just cut them with an X-Acto blade,too. Do any dying now, and let fully dry before asesmbly.
Keeping the leather pieces in order, slide the stack onto a piece of wire or dowel. Set aside the sword.

Coat the two washers and the mandrel with some sort of epoxy release agent. You can dip them in melted wax, or coat them with several coats of car wax.This is to allow the mandrel to be removed once the handle is cured.

Mix up a batch of slow set epoxy in a plastic container wide enough to easily reach into.You want one hour minimum set time, longer is better. What works best is fiberglassing resin. It is thin and sets reasonably slow. I recommend System Three Clear Coat. Woodcraft Supply carries it. It can be thinned,too.
Whatever you use, mix enough to do the whole handle in one opperation.

Put on rubber gloves. You will need to have them.

Have a helper drop the leather pieces in the epoxy one at a time. You will dunk it in the epoxy, wipe off the excess, and slip it on the mandrel, sliding it down to the guard washer.While you do this the helper will drop in the next leather piece. This will go really fast once you get the rhythm going. Continue until all the leather is on the mandrel. Slip on the top metal washer, and thread on the nut.Hand tighten it. Wipe off the excess epoxy from the leather and the mandrel parts. Put the "Blade" part in a vise, and snug down the handle by tightening the nut. You don't need to go any tighter than necessary to compress the leather pieces snugly together. Wipe the exposed threads on the mandrel well with acetone, and give the threads a little spritz of WD-40 (this will make removal of the nut much easier later).

Check the epoxy pot regularly, and when it is set, but not cured (it should just have just stopped being tacky), take off the nut , and screw on a piece of threaded tubing about 1" long (1/4-20 coupling nut works perfect). This is just for the purposes of striking the end without damaging the threads, and nearly anything will work. I just like to have about 1/2" of the threads engaged. Loosen the vise and set the "guard" washer against the jaws, with the "blade" loosely between them. Strike the threaded end gently with a mallet. It usually comes loose easily. If needed, strike a little harder. You are not going to take it off, you just want to break any grip the epoxy might have. Once it has moved about 1/2", put the nut back on and tighten things back up. Set aside to cure for a couple days at 70-80F.

Once all is hardened, take off the mandrel and clean the mandrel with acetone. Put the handle back on the mandrel ( leave the metal washers off) and rough shape it on the belt grinder. Now, test the handle on the actual sword tang. If all is well, it should be a forced fit. If it is too snug, file the inside with a riffler file. Shorten the length to the exact fit desired. Put back on the mandrel for further shaping and sand to about 400-600 grit. Work in a protective and conditioning coat of bag balm ,or similar leather treatment, and let dry.Give it a buff with a soft cloth, and assemble the sword.

This make a very strong and grippy sword/knife handle.

Stacy
 
Perhaps it would go good on a hand and a heifer sword.
You guys know I wouldn't steer you wrong....No Bull.
Stacy
 
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HAHAHA LOL, Moocarta, that is the best!!!! You guys have terrible senses of humor :D

Thanks for the info Stacy, I will be giving stacked leather a try on the next one using that method.
 
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