Thanks gents.
Let's move to the saga of the saya. Mark (itsaburl) was kind enough to send Stuart a long block of walnut that he felt might serve.
Stuart sent me the pic:
I was all, like, "Umm, uh, well it's definitely wood... but.., ah...."
Well, Stuart assured me that it was MUCH more promising in person than the photo suggested - some nice figure and colour, etc.
I was still, like, "Um, are you suuuuure?"
But I know two things" Mark knows his stuff and so does Stuart. Both of them had the wood in hand, I didn't. I said roll with it. As you will see, I would be very glad that I did.
Before we get to that, though, here are a series of pics of fitting the horn collar on the saya. Stuart explained the traiditonal use of this material in this application:
By the way, the buffalo horn pieces I was going to use are bought directly from a Japanese sword fittings supplier and are used on almost every saya without issue. The reason it's better than wood, in this application is that when banding the mouth of the saya, the piece gets quite thin. Wood grain would be weak at those points and negate the purpose. The homogenous structure of the horn doesn't have the "grain" weakness problem and as such serves the purpose to strengthen the weakest, most stressed part of the saya.