Mekugi

[Ly de Angeles]

I'm hunting up a supplier in Australia for already made mekugi. Got all the info on how to make them for myself but the one that's currently in my tsuka is worn and one slip and ...

Once I've studied one in my hands I can make. Anyone advise on local supplier?

Regards,
Ly

[chidokan]

I use either bamboo chopsticks or the outer edges of broken shinai. Do not use the inside as it is too soft. If you look at the top section of the bamboo when you cut it across the grain, you can see the colour and grain change... you'll see what I mean about the outer skin that way.. then scrape it down with a sharp knife until it fits precisely. Dont use sandpaper....its a guaranteed way of damaging the blade as those dust grains get everywhere!

[Ly de Angeles]

Thanks heaps, I'll give the chopsticks a go as they're easy to get where I live (as is live bamboo).

Ly

[chidokan]

the best way to make one is in three parts, that way you get the best bamboo all the way through. I cant be bothered, its too fiddly for a guy with big hands... allegedly they last longer though..

[Ly de Angeles]

Hey Chodokan, I'm going to sound really dumb here but ... make one in three parts? Please can you explain? (Otherwise I'm thinkin' I'll have to go commercial!)

Ly

[chidokan]

think of a circle... divide it into three equal (120 degrees) parts.... thats what the top view looks like. It only uses the outer 'skin' of the bamboo. does that make sense??? :puzzled: These are the 'posh' versions used on top notch shirasaya. If you have a go at one let me know if you succeed...

[Ly de Angeles]

I sure will. Getting started already. I spent this evening talking with one of the Senseis from the Adelaide dojo (Byron Bay's another two states away so we're kinda orphans with 10 waza to perfect before one or another of the guys come up for recon.) and he basically said what you have told me so thanks heaps.

Another thing, if you would advise ... my live blade is about a 100 years old but has been fitted out with cavalry saya although the tsuka is the original (and is pretty awesome). I want to be able to put the saya away and make one. I'm cool on the correct woods (have a great supplier of exotic and hardwoods) and the glue, and have some good tools but, other than buying a cheap sword and throwing it away and cutting the saya up to get a pattern is there any source for same? I'm not so much a *purist* although could be accused of being pretty anal when it comes to this, but basically a.have spent all my loose money on the live blade, b. everyone who specialises in making fittings wants the iato in front of them and c. (rightly so) charge more than I can afford (upwards of $300Aust) plus I don't want to send the thing away to strangers no matter who they are.

Thankyou <bows>
Ly

[chidokan]

saya are a lot more work than they look, but if you have some basic tools its fairly straightforward. Cut out a rough area that will get all the sword in. Plane the edges flat as you are going to split this down the middle looking from the final top of the saya as in the belt. split the plank. place blade on one inside surface, draw around it and either use a router to give a quick cut or labour away with a small chisel. Dont cut too deep and follow the profile of the sword half. Put the other half of the split wood on top with the blade in the recess and flip over, mark out the other side and cut it out. put it all back together, bind the outside, and make sure the sword goes in and out smoothly. add the habaki and shape that area on both pieces of wood in the same way as before. once you have a firm fit with no 'sticking', remove the blade and glue the halves together. check once dry the blade still moves o.k. then start planing down the outside. I use a slight 'notch' to locate the kurigata before gluing that in. Someone in the States sells buffalo horn for koiguchi reinforcement and kurigata quite cheap, cant remember who it is tho! :D Hardest part is the lacquering.... make sure the saya is as smooth as possible and give a good couple of sealing coats before even thinking about using lacquer. Think theres a good book on this somewhere "craft of the japanese sword" but this is for shirasaya, although basic techniques are there. good read as well.

[Zuyax]

I just found this forum, so first I would like to say Hi to everybody.

Ly de Angeles, if I may ask a question, you mention that you have a good supplier of exotic timber for your saya. I am just wondering if they stock Honoki wood and if they are in Byron bay? I am currently remounting one of my swords and am having a hard time finding suitable timber for the project and if there is somewhere in byron who sells it that is fantastic as my family live down in Brunswick heads and I often travel down there to visit.

Cheers, Josh

[chidokan]

same for me, but the guy asked me what I was doing with it. He recommended a certain type he had in stock that was specifically bought for people who whittle wood, that is to say you can carve it any way you like without having to worry about it splitting etc due to the grain structure. it came out o.k., so next time I buy some I'll find out what its called! :rolleyes:

[Zuyax]

Ok that would be good. I have been using Syrian Cedar with some good success for koshirae-saya. Its very light in weight and quite soft so it carves wonderfully, but on the most part it is quite dark in colour (dark pink/red) so visually it isnt that great for shirasaya.

Cheers, Josh