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Description
Sandwiching

Many of you have asked for a "how to make a scabbard" tutorial, so I have decided to draw it up with my doodle like tutorials. There are in total 3 different ways to make a scabbard successfully.

Sandwiching is by far the easiest approach to making your own scabbard. However it is by far the weakest type of scabbard, just try to avoid accidents. You are basically going to have 3 layers of pinewood where the center one is cut out into a "U" shape so that the blade can slide into it. The other 2 layers of pinewood encompass the blade.

Step 1: Grab 3 pieces of pinewood 5mm in thickness and draw about 5mm away from the edge of the blade outline on both pieces of the pinewood. Make sure when the pinewood are layered together that the total thickness should be about 15mm. Make sure to draw the outline perfectly on all 3 parts.

Step 2: Now grab one of the pinewood scabbard parts and draw the outline of the blade onto the wood about 1mm or 2mm away from the blade. You would be drawing the scabbard part again only smaller and inside the original one. This will be the center scabbard piece where the blade will live in.

Step 3: With a coping saw, cut out both the pieces of the pinewood scabbard parts first not including the center piece. Then for the center scabbard piece cut out carefully the inside out of the wood. The center scabbard piece should resemble a “U”. You have to make sure as to not snap this delicate part.

Step 4: Now the habaki must fit snuggly onto the entrance of the scabbard. So chisel out some room for the habaki to slide and lock into place. Then you must test and see if the blade from the katana can slide through easily and the habaki. If it doesn't then you must remove more of the pinewood until it does.

Step 5: Then get all 3 parts of the pinewood scabbard together with the center scabbard part in the center and combine them on top of each other. Make sure that they all 3 parts align correctly, if not sand until it does with sandpaper. Also make sure there is enough space to allow the blade to slide in and out

Step 6: Now with woodglue apply it on your finger and massage it onto the sides of the pinewood scabbard pieces. Once enough glue has been placed, carefully position the scabbard parts together then sandwich them together. Compress really hard and wait for the glue to dry before moving on.

Step 7: If you notice the other end of the scabbard has a gaping hole. So you must cut out a wooden peg from pinewood to enclose the end of the scabbard and stick into position with wood glue. You have to make not to push the wooden peg in too much or you will not be able to get it back out.

Step 8: Now with hand files round all the sides of the scabbard until it is oval shaped. Then use grades of sandpaper from the most course to the most fine to smooth the sheath. The scabbard should be as smooth and round as possible. The sides of the scabbard can be covered with wood filler.

Step 9: Finnaly, Apply white primer spray paint. Apply several coats until grain is not visible, the inside is not needed. Next apply the appropriate coat of coloured spray paint. Then finally apply a hard protective clear gloss on the sheath. Once everything is finnaly dried you can test if the blade slides into the scabbard parfectly.

Description
Sandwiching

Many of you have asked for a "how to make a scabbard" tutorial, so I have decided to draw it up with my doodle like tutorials. There are in total 3 different ways to make a scabbard successfully.

Sandwiching is by far the easiest approach to making your own scabbard. However it is by far the weakest type of scabbard, just try to avoid accidents. You are basically going to have 3 layers of pinewood where the center one is cut out into a "U" shape so that the blade can slide into it. The other 2 layers of pinewood encompass the blade.

Step 1: Grab 3 pieces of pinewood 5mm in thickness and draw about 5mm away from the edge of the blade outline on both pieces of the pinewood. Make sure when the pinewood are layered together that the total thickness should be about 15mm. Make sure to draw the outline perfectly on all 3 parts.

Step 2: Now grab one of the pinewood scabbard parts and draw the outline of the blade onto the wood about 1mm or 2mm away from the blade. You would be drawing the scabbard part again only smaller and inside the original one. This will be the center scabbard piece where the blade will live in.

Step 3: With a coping saw, cut out both the pieces of the pinewood scabbard parts first not including the center piece. Then for the center scabbard piece cut out carefully the inside out of the wood. The center scabbard piece should resemble a “U”. You have to make sure as to not snap this delicate part.

Step 4: Now the habaki must fit snuggly onto the entrance of the scabbard. So chisel out some room for the habaki to slide and lock into place. Then you must test and see if the blade from the katana can slide through easily and the habaki. If it doesn't then you must remove more of the pinewood until it does.

Step 5: Then get all 3 parts of the pinewood scabbard together with the center scabbard part in the center and combine them on top of each other. Make sure that they all 3 parts align correctly, if not sand until it does with sandpaper. Also make sure there is enough space to allow the blade to slide in and out

Step 6: Now with woodglue apply it on your finger and massage it onto the sides of the pinewood scabbard pieces. Once enough glue has been placed, carefully position the scabbard parts together then sandwich them together. Compress really hard and wait for the glue to dry before moving on.

Step 7: If you notice the other end of the scabbard has a gaping hole. So you must cut out a wooden peg from pinewood to enclose the end of the scabbard and stick into position with wood glue. You have to make not to push the wooden peg in too much or you will not be able to get it back out.

Step 8: Now with hand files round all the sides of the scabbard until it is oval shaped. Then use grades of sandpaper from the most course to the most fine to smooth the sheath. The scabbard should be as smooth and round as possible. The sides of the scabbard can be covered with wood filler.

Step 9: Finnaly, Apply white primer spray paint. Apply several coats until grain is not visible, the inside is not needed. Next apply the appropriate coat of coloured spray paint. Then finally apply a hard protective clear gloss on the sheath. Once everything is finnaly dried you can test if the blade slides into the scabbard parfectly.