Cutting a Channel into the timber handle for the steel rod.
As the blade of the sword has a steel rod running its length the intention is to continue this length through the handle of the sword to hold the entire object together. The handle of the sword has a timber core, which is 25cms in length and needs a hollow core which is 3/8 inchs wide to accomodate the threaded steel rod.
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| This is the timber sword handle core held in a vice, note that either side of the timber there are pieces of timber, this is to reduce damage caused by the vice, without it the vice jaws would leave bruising and scoring on the surface. |
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| ABOVE: The sides of the channel were cut using a regular wood saw. Making sure to cut on the inside of the marked line for the | 3/8 inch channel and cutting only halfway through the timber of the sword handle core. |
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| ABOVE: The next step was to carefully chisel the channel, making sure that I cut at a 45' angle and gently levering the timber free, remember to always cut across the grain in this stage. The intention is to remove all of the timber in the center of the two lines running the length of the image above |
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| ABOVE: once the bulk of the timber has been remove now chisel the center going WITH the grain, this will make for a clean cut channel and reduce unwanted splintering |
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| ABOVE: continue this process until a channel has been carved halfway (10mm testing with a depth guage for consistancy) |
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| ABOVE: The next step is to use a rounded file and file out the rest of the channel, so that it will be a tight fit for the steel rod/sword blade core |
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| ABOVE: NOTE in the image above, the channel for the cross guard has been filed wider to acommodate for the curve (pictured BELOW. |
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