How to Make a Sheath for a Samurai Sword
- 1). Put the wood block on a work table. Cut out a piece of wood that is the same length and width as your Samurai sword using a power saw. Cut out two pieces of wood that are identical to the first one cut.
- 2). Cut out a piece of wood that is the same width but one inch longer than the Samurai sword with the power saw.
- 3). Place the three identically cut pieces of wood vertically on the work surface with their sides butted up against each other. Butt the bottom end of the one-inch longer piece of wood against the bottom end of the piece of wood on the right side.
- 4). Place the sword, tip facing towards you, on the one-inch longer piece of wood. Line up the notch on the sword's blade with the top edge of the wood.
- 5). Measure one inch past the tip of the sword on the wood. Make a mark with the pencil at the one-inch mark. Remove the sword from the wood.
- 6). Draw a horizontal line across the pieces of wood using the mark on the piece of wood with the pencil.
- 7). Put the end of one of the pieces of wood farthest from the pencil mark in the jaws of the vice. Close the vise. Cut off the piece of wood at the pencil mark with the power saw. Repeat this procedure with the other pieces of wood. Discard the cut pieces of wood.
- 8). Sand both ends of the wood pieces with the rough sandpaper.
- 9). Place the piece of wood that is one inch longer than the rest vertically on the work table. Place the Samurai sword on top of the piece of wood. Line up the exposed blade of the sword where it meets the handle against the end of the piece of wood.
Make a mark at either side of the sword where the exposed blade meets the end of the piece of wood with the pencil.
Apply bonding glue to the left and right sides of the piece of wood.
Place a piece of wood on each side of the one-inch longer piece of wood so that the ends of the two pieces of wood line up with the end of the one inch longer piece of wood closest to you.
Let the bonding glue set for three hours. Remove the sword from the piece of wood.
Apply bonding glue to both ends of the one-inch piece of wood. Line up the final piece of wood onto the top of the one-inch longer piece of wood. Let the bonding glue set overnight.
Pick up the sheath you have made for your Samurai sword. Insert the tip of the sword's blade into the slot at the end of the sheath, and push in the blade.