Notes for making Tsuka and Saya (woodwork)

Day-1

Making Tsuka and Saya (woodwork) are basically similar and done around 2 days for wood work, and the followings are the summery of noticeable comments by the Japanese Tsuka-shi, Saya-shi (craftsmen) of our Tsuka and Saya making class in Japan for typical Muromachi era Itomaki Tachi using WWII(1940's) Seki swordsmith blade.
(Making Tsuka and Saya are slightly different from each school which craftsmen belong to, by process, style, know-how.)

---

Wooden boards Making Tsuka or Saya requires the same size of smooth surface two wooden boards, which may not be hard wood or tropical wood. Note: Always sandwich inner growth ring of wooden boards (curving sides), in order to minimize bend and maximize strength.

---

Drawing boards Placing blade on boards and start drawing to curve, considering Shinogi, Ji, and Habaki size.

---

Shinogi and Nakago Note: Before curving, review the shape of Shinogi (Tsuka: review the shape of "Nakago" tang) for curving depth.

---

Drawing for cutting Marks Finally, draw the cutting marks/lines on outside of boards, considering cutting accuracy.

---

Curving and bonding 1 Curve accurately, considering moving space of blade using curving tools (Tsuka: certain friction is desirable.). Many different type of curving tools are available from traditional hand tools to electric powered tools. Then, glue two boards with Japanese rice paste. (Mightbe use mixed half Japanese paste and half carpenter wood glue for fast bonding.)

---

Curving and bonding 2 After carved boards, sanding each surface smoothly for glue securely, and bonding tightly using clamps. Glue time is one night, and continue to work the rest of woodwork in next day.

---

Notes for making Tsuka and Saya (woodwork)

Day-2

Cutting Cut the marked Saya external lines, it is desirable to consider some space (1-2mm) for filing and finishing.

---

Forming After cut boards, start forming (planning/filing). Note: First to finish the Habaki entry, using Japanese riffler rasps.

---

Sanding After formed shape of Saya and Tsuka, sanding the surface of wood to be ready Urushi paint (decoration). (Urushi requires smooth shinny surface.)

---

Fitting Before and after check all necessary fitting are in order to meet Saya and tsuka. Below is each fitting area.

Completed Tsuka and Saya wood work

After Day-2 for decorating Tsuka and Saya

---

Decoration Tsuka should be wrapped with Same-kawa and Tsuka ito or decorate Tachi style tsuka fitting. Saya would be painted Urushi (Hon-urushi (Nama-urushi) or cashew urushi) considering fitting. Below is example of type of Urushi painting.

---

Cashew Urushi coating sample

Day 1 - Shitaji (Base coat) In order to make harder coating surface, paint Cashew "Shitaji 2go" (Undercoat 2go), which is cashew resin putty. Left picture is Cashew Undercoat 2go coated Tachi Saya. Note: Katana, Wakizashi saya may wrapped by Yoshino-gami before Shitaji coat to reinforce saya for preventing cracks, due to non reinforce fitting, such as Ashi, Kashiwaba, Semegane of Tachi saya.

---

Day 2 - primary coat Paint Cashew "Surfacer" on Undercoat 2go, in order to make primary layer. Left picture is Cashew Surfacer coated Saya on Undercoat 2go.

---

Painting style of Urushi color on Saya

Note: Please refer to respective published books, videos or each professional's site for more details to woodwork, Urushi painting, Tsuka maki.

Go to Fitting Adjustment