Here is a saya making WIP to help everybody with the HHH saya making challenge. I am also planning on putting several other WIPs in this thread, one at a time of course.
This is going to be for a 3 piece saya.
Ok here are my materials. I have some chakte viga for the sides and basswood for the center
make a cut out in the center layer so that the saya will be longer than the blade so there will be room to drill the pin hole, then trace the blade. This needs to be rather accurate so that you can get a friction fit.
Now trace another line about .25-.5 inches outside of your original line. This does not need to be exact if you don't want it to be, it will be sanded down during shaping.
Now cut along both lines, be precise on the inside.
Checking to make sure it fits.
now glue your middle layer to one of your side pieces. I did a little more cutting and some early shaping during this step also.
While the glue is still wet put your blade inside and make sure it fits perfectly.
Clamp and let dry.
Double check your fit.