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
Category Archives: Handmade Tools
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 couple of mm oversized, compressed by hammering, and then… Continue reading
Making a Swordsmith Anvil from Scrap
A Japanese swordsmith style anvil made from junkyard scrap. The two side pieces are cast steel or iron John Deere 8255C rear counterweights from a shovel dozer. They weigh about 200-240lbs each and measure about 2 1/8″ x 14 3/4″ x 25″. There is a ‘T’ shaped face and stem that extends to the ground between the plates made from welded spring or tool steel and weighs about 70lbs.
The face is about 1 3/8″ x 6″ x 15 1/4″ and has a pritchel hole in it and a sharp edge for cutting on one corner. The combined weight of the plates bolted onto the face and stem should be between 475 and 520lbs. The finished anvil should sit 7-7.5 sun from the ground or from the seat height. See the whole forge building process here.
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 of wetlands, streams, forests, and fields… 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 the four wooden flap valves, called… 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 and hatchet handle design theory and… 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 of the work, keeping it clean… Continue reading
You Need A Swordsmith’s Fuigo Box Bellows
Japanese style box bellows (fukisashi/吹差鞴) reached their current and finalized form by about the sixth century. They are constructed almost entirely of wood and allow a smith to supply a highly controlled air blast to the forge by pulling and pushing the handle slowly back and forth. Using… Continue reading