Polishing and restoration process of a very large sword
(This sword has a Nagasa of 40"long. The with at the habaki area is about 2-1/2" wide)
This sword was badly in need of a polish. After removing
rust and some chips I repaired the kissaki that was broken.
This picture shows the sword ready for final shiage-togi (finishing polish).
These are some pictures during the first steps of polishing.
At this point I am making a wooden habaki in solid Ebony for this sword. I will do the final polish of this sword after the habaki and shirasaya is completed. I have not seen any other craftsmen using ebony for habaki. My clients like the end result after I make matching inlays in the shirasaya handle and make the mekugi in ebony also.
The habaki is being fitted to the sword.
The habaki is ready to be glued together with a special glue that I like to use for ebony.
After the glue dries I can then shape the habaki.
This is the final shape of the habaki before it is polished and given a fine finish. Shirasaya and habaki will be polished together at the end.
This is the completed ebony habaki.
The Shirasaya wood is so large that it is very difficult to carve out the inside in long even strokes. Slowly the wood is carved carefully so that the sword doesn't touch the wood on the inside when it is glued together but the sword shouldn't rattle either inside the saya. Also consideration has to be given to the way wood changes with the climate. The fit has to be very good to protect this sword and its new polish.
This is the completed Shirasaya measuring over 60" long. Now I'll give may arms a rest for a few days!
With the completed Shirasaya I am finishing the polishing work on the sword at this point. Below you can see some pictures of the process but if you want a better detailed understanding of the polishing process click on "Polishing, step by step".
This is the fully polished sword ready to send back to its owner.
This sword was on displayed at the Chicago Sword Show 2007.