Nygen's Scabbard Tutorial

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#1 Nygenx on 10 years ago

#2 Nygenx on 10 years ago

#3 Nygenx on 10 years ago

Advanced Technique: Wood Bending.
This is necessary when you are working with the wooden guide rails. You may notice that the wood may start to crack or break when trying to get it to conform to your cut out. If this is the case, you have one of three options.

[LIST][*]Option One: You can choose to break the wood and then cut off the splinters and excess after it has been cut. Then later on, during the fine construction stage, you will have to fill the area.

[*]Option Two: Ghetto Wood-Bending. I am not an average person, when it comes to tool possesion, however I do not expect an average person to have the tools I have. For the common person, ghetto wood bending is your solution. It is a process done by first cutting a piece of wood in the contour you need to be able to bend to. You then boil a pot of water on high till it is bubbling and releasing plenty of steam. WEAR HEAT RESISTANT GLOVES WHILE DOING THIS. Now get tie wraps and wrap the guide rail to the wood you had just cut out as tight as you can, without breaking the wood. After a while you should be able to tighten the tie wraps a bit more before the wood would break. Eventually you end up with THIS [IMG]http://i89.photobucket.com/albums/k216/nygenx/Scabbard Tutorial Pictures/DSCF0690.jpg[/IMG]
[IMG]http://i89.photobucket.com/albums/k216/nygenx/Scabbard Tutorial Pictures/DSCF0691.jpg[/IMG]

[*]Method 3: "Real" wood bending. True wood bending is done by submerging wood in boiling water and then clamping it down after being removed. Its obviously quite dangerous, and I do not expect anyone to be able to do this. You can also use a steamer to do this, but it wont get as much bend.[/LIST]

Tips for Picking the Right Wood

I recommend using either pine, maple, or poplar for the main pieces of the scabbard. A piece of wood that is good for the two main pieces is generally about a quarter to an eight of an inch thick. The thickness makes the scabbard look less bulky and more realistic. The wood you purchase should be called "craft wood" and comes already smooth. Home Depot and Lowe's both carry it in four foot lengths. It is possible to get even thinner wood, but generally that has to be home-made. With home made wood, it is necessary to sand it down till its smooth.

You should also take care to make sure the wood is as straight as possible. You can check to make sure that the wood is straight by two tests.
[LIST][*] Lie the piece of wood on FLAT ground, and press down at various points on the wood. Then flip it over and repeat. If the wood pushes down or comes up at all, then it is not flat.
[*]The second test is using line of sight to look down the plane of wood. When you flip the wood over, if it looks at all distorted, it is bad.[/LIST]

The side rails should be made out of a softer wood such as pine. Balsa is also acceptable and is easier to cut, yet you will need to apply putty over it, as sanding will never be totally smooth from its grain type.

Reserved...For Advanced Techniques, Alternate Methods, Alternate Materials and Power Tools Guide.

#4 Nygenx on 10 years ago

Reserved. This is a big guide in its entirety, when its all up.

#5 Chipface on 10 years ago

Wow that's a very detailed guide. I've got a question though. Since it doesn't really look like you lined the inside of fabric, did you sand the inside of the scabbard smooth to protect the blade's paintjob or is that not neccesary?

#6 Nygenx on 10 years ago

Right now im creating a materials list ^_^. If you purchase wood from a store like home depot, it is not really necessary, given you've coated the sword with enamel. The craft wood they sell is already pretty smooth, so theres no need to sand it down. The edge of the blade and top might get scratched up, and its possible to prevent that with some fabric. So far I've done it once, when I had to after using a router to hollow wood. It did not turn out *that* well. I do however, intend to use a fabric lining when making Nel's sword. When I do, Ill post how to ^_^