Building a Togi-Dai for Polishing

Togi (研ぎ) is the process of using several stages of abrasive stones to refine, smooth, and sharpen a blade. The word togi does not differentiate between the action of polishing and the action of sharpening, in the Japanese concept the operations are… Continue reading →

Organizing the Carving Area for Making Saya

A few views of the preparation of the woodworking space for carving saya (scabbards) and tsuka (handles). The loft area of the shiageba provides a small floor working space and storage area for tools and wood while downstairs is for polishing. The… Continue reading →

TLDW #27 – Forging a Saya Nomi (鞘鑿)

Saya-nomi (鞘鑿) are a type of Japanese chisel with several unique features designed for carving the inside of a wooden scabbard or handle. Hand forged from a reclaimed harrow tooth, the elongated neck is slightly curved for clearance and the bottom and side corners are slightly rounded and the tip is slightly bull-nosed to facilitate cutting inside a concave surface without leaving corner marks. A scrap of magnolia makes a clean, simple handle for use as a push chisel. more about the process of carving saya (scabbards)

Glass Top Fuigo – Inside View of Box Bellows

A look at the inside operation of a prototype fuigo (鞴) box bellows…four wooden flap valves (called ben / は弁), two for intake and two for the manifold, control the direction and location of the airflow on each stroke of the piston to provide double action to the single output into the fire.

more about fuigo | making valves | fuigo archives

Making a Kanna from a Reclaimed Chisel

A custom mameganna (small “bean” plane) such as might be used by furniture makers can be made fairly quickly from an old chisel. This type of kanna might be used for shaping saya or tsuka or for other small woodwork projects requiring… Continue reading →

Process: Carving the Tsuka & Saya – Aikuchi Tanto Koshirae

In this video the tsuka is carved first, starting with the fuchi end and then the kashira area, carving the profile outlines and then removing the material in between before carving the final shape and sculpting the details. The saya is next, first dimensioning the blank is to approximate size and then profiling the koiguchi and then the kojiri, removing the material and carving as close as possible to the final shape using kanna and kiridashi. Finally any remaining high points in the curves are smoothed with a fine rasp. carving the inside | making the fittings | final work

Process: Carving the Inside – Aikuchi Tanto Koshirae

In this video the tsuka is carved first, starting with the omote side and then the ura, carving each half from the mune to the ha. The saya is next, starting with the omote and then the ura, each half beginning with the fitting of the blade (from the mune towards the ha) and then the fitting of the habaki area (koiguchi). Finally the halves are glued together with rice paste glue, wrapped with leather cord, and wedged tightly to dry overnight. The first half is almost real time, the repeat steps edited out during the second half. The wood is hounoki, carve carefully and check often! carving the outside | making the fittings | final work

Making a Handle for a Japanese Swordsmithing Hammer

Traditional Japanese swordsmithing hammers have rectangular eyes with no taper. The handles are not wedged but are held in place by a compression fit involving careful shaping, hand forged wood, and soaking in water. The wood is shaped a mm or two… Continue reading →

Tools for Satoyama

Satoyama are the managed forest areas that border the cultivated fields and the mountain wilds in Japan. Historically they provided fertilizer, firewood, edible plants, mushrooms, fish, and game, and supported local industries such as farming, construction, and charcoal making. Balancing the interaction… Continue reading →

Making Valves for Fuigo Box Bellows

Fuigo (鞴, Japanese box bellows) are among the most compact and efficient hand-powered bellows for forging work. With few complex or moving parts, they are easy to maintain and will provide years of service. Among the more technical points of construction are… Continue reading →

Making a Hatchet Handle

The second half of the antique hatchet restoration project. There are several important points that are often overlooked when choosing or crafting an axe or hatchet handle. Though not a thorough treatise on the subject, this post will briefly discuss some axe… Continue reading →

Making a Bamboo Water Scoop for Water Forging

Forging with a thin film of water on the anvil and hammer prevents forge scale or oxide from being hammered into the surface of the steel. The hot steel instantly vaporizes the water and the resulting steam explosion blows the scale off… Continue reading →

Crossed Heart Forge

Charcoal forged classical tanto & fusion style takedown knives crafted by hand from reclaimed steel and natural materials using traditional techniques.

Category Archives: Handmade Tools