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Thread: Saya ventures!

  1. #1
    Senior Member RoanRoks29's Avatar
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    Saya ventures!

    I wanted to get some practice in with wood working, so I decided I would try to make a saya. So I started making one for my 8" shun.

    Traced it out , then cut it

    Then retraced it to see where I need to carve out to fit the knife!Hours of work later, I lined it with some smooth maroon felt then glued it together sanded it down and cleaned her up a bit . So after making that one I had some small peices left over and figured my little petty need one too. This time I changed the design a bit an add in two little notches in order to make it easier to pull off. The two sayas with the felt fit like gloves and I orginally planned on putting in pins but they were unnecessary.

  2. #2
    Get some 1/8" thick wood from Rockler or WoodCraft. I find 1/16", 1/8" and 3/16" BassWood (or another soft wood to be easy on the edge) work pretty well as a spacer and the 1/8" thick woods work well on the outside Soooooo much easier than carving it out! WoodCraft also has a bent chisel for like $15 that I found that will let you chisel something like that out easier than a straight chisel supposedly, but I haven't tried it out.

    Also, watch the felt. I have some Dexter blade guards with the felt on the inside. I put some of my cheap carbon Green River kitchen knives into them and they rusted a lot after a few weeks. I had dried them, so I don't know if I missed a spot or if moisture got in there somehow. I only use them on SS knives now, or for transport and then take them out for storage.

  3. #3
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    I would worry about the felt holding onto debris and scratching the blade, and also the rust from ambient humidity. Better than my saya, since I have only bothered to cut magazines to size for my blades that need a saya.

  4. #4
    Senior Member RoanRoks29's Avatar
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    Herd ... I get ya on the felt I wish I thought about it picking up moisture before hand, but as they say hindsight is 20/20 aye hahaha. The wood is basswood and it was pretty easy to carve out. I was thinking about doing the spacer piece but was feeling a little ambitious, plus I want it to fit snug. A friend of mine has a saya with a spacer and it wiggles so much in it. I am gonna make another one now though and leave the felt out.
    Quote Originally Posted by GlassEye View Post
    I would worry about the felt holding onto debris and scratching the blade, and also the rust from ambient humidity. Better than my saya, since I have only bothered to cut magazines to size for my blades that need a saya.
    I used to do something simular I used cereal boxes, duct tape and some plastic bottle pieces to help from the knife cutting through!

  5. #5
    The spacer method is much easier IMHO and I get the basswood in a few different thicknesses. You can always sand down the spacer to make a tighter fit, too.

    I did the cardboard and duct tape sheaths years ago, too!!!

  6. #6
    It might be a little easier to carve the cavity on one side only, so you don't run a risk of wood shifting during glue up and affecting the fit.

    M


    "All beauty that has no foundation in use, soon grows distasteful and needs continuous replacement with something new." The Shakers' saying.

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  7. #7
    Quote Originally Posted by Marko Tsourkan View Post
    It might be a little easier to carve the cavity on one side only, so you don't run a risk of wood shifting during glue up and affecting the fit.

    M
    This is exactly what I was doing. Glad I'm on the right track...

  8. #8
    Senior Member RoanRoks29's Avatar
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    So I just made a new one with the carving one side technique and I am very pleased with the results and it was soooo much easier!!!


  9. #9
    Quote Originally Posted by RoanRoks29 View Post
    So I just made a new one with the carving one side technique and I am very pleased with the results and it was soooo much easier!!!
    Yes, it is.


    "All beauty that has no foundation in use, soon grows distasteful and needs continuous replacement with something new." The Shakers' saying.

    If my KKF Inbox is full (or not), please contact me via Email: anvlts@gmail.com

  10. #10
    I learned a good lesson today. I made a saya out of three pieces of Italian bending poplar which is nominal 1/8" for my Honyaki gyuto and the slightly blade is thinner than the middle ply. It worked out quite well with even a little side to side play. Then I figured WTH and made one for my Kiritsuke. What I learned is measure the tang at the ferrule!! While the blade is thin it gets wider at the tang and I had to fiddle with making something with sand paper to widen that part of the saya . . . Doh!!! This is where calipers are handy and barring that one could make a go/no go gauge for a particular knife. Oh well - learn something new every day even if it's the hard way.

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