Tuesday, July 7, 2015


One of the last things I do is put the final edge on and sharpen. This knife will behave well with a low angle cutting edge. I am aiming for 15°. I use a Norax 45 micron belt for this. That's about a P320 grit.

Once the wire edge is on, I give it a stropping with the MDF sharpener and a little white compound. Razor sharp now.

The final touches include a coat of renaissance wax and a buff.

Making the Saya

A saya is a sheath or covering for a knife to protect the knife and any careless handlers. It is traditionally made of wood, but can be plastic or synthetic nowadays. One way to make a saya is to hollow out a piece of wood to match the shape of the blade and add a cap to it. Another way is to make a three-layer lamination and cut out from the middle layer.
I started with three 1/8" slices of oak. I ripped them on the table saw. Here I have cut out the shape of the blade in the middle layer.
Then glued and clamped the middle layer to one outside layer. I used outdoor rated glue as this will be in a kitchen environment.
Here is a shot of the knife sitting in the "pocket."
A trace around the outside with about 1/4" or about 6mm of extra material. This line follows the shape of the blade and will be guide for cutting out the finished saya.
While still in two layers, drill the hole for the pin. This is for some 3/16" dowel.
Now cut the shape on the band saw.
This is the view from the opening end after cutting out the basic shape.
Now, glue and clamp to the third piece to complete the lamination. When the glue sets, cut the last piece back to shape. You may use a sander to bring the shape a little closer to the pocket.

Here the pin is fitted and waiting for some fine sanding and a protective stain.

I chose a rosewood stain to go on the oak. I wanted it to look similar to the handle tones. 

As always, there are dozen ways to do something. This method worked okay, holds well, was relatively easy to do and looks good.

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