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Post by chrisperoni on Apr 10, 2015 5:33:51 GMT
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Post by Cottontail Customs on Apr 10, 2015 5:42:53 GMT
Very cool! Is this for a ken?
-Josh
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Post by chrisperoni on Apr 10, 2015 7:20:23 GMT
Yeppers.
2.5 years ago I bought a folded t10 ken from huawei and I've been sitting on it all this time. Always intended on outfitting it myself but never got around to it. The blade is stunning, with clean lines and a very well done bohi, so I knew I would never sell it. The hamon is amazing and there's nie and nioi and all that nice stuff you see in sweet japanese style swords. The saya is broken (from shipping) and will need a lot of work, as will the tsuka which is just their plain rosewood kind. Going to make all the fittings, reshape and wrap the tsuka as well as repair and samegawa wrap the saya. I'm also hoping to make a tachi-esque strap from leather for it-- but that would be extra and I'll still call the sword done even if I don't get to that bit.
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Post by Bryan Heff on Apr 10, 2015 9:50:28 GMT
Fun with a drill press. Looks great so far! I love watching threads like this, seeing how people get things done in their particular shop. Everybody has different tools and techniques but the bottom line is figuring out a way to make it happen. We don't all have a fully blown machine shop or forge with all the bells and whistles...that's for sure.
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Post by chrisperoni on Apr 10, 2015 14:11:58 GMT
I wish I had a proper metal cutting band saw for the initial cut out of the piece of copper. Mine is just not strong enough for anything more than 1/8" thick metal. Instead of at least buying a different blade, I just used a hacksaw. It was slow going for the first cut so I wasted some material but saved time with a bunch of holes.
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Post by DigsFossils-n-Knives on Apr 10, 2015 15:59:12 GMT
Bi-Metal Hole Saws (link) You can get them in almost any size: I use them all the time for non-heat treated steel. Sometimes 0.5" thick.
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Post by chrisperoni on Apr 10, 2015 17:37:15 GMT
I should look for those for next time. I have about a dozen mild steel plates that I want to cut tsuba blanks from and that would make it much easier. Not too expensive either - about the same cost as a basic metal cutting bandsaw blade. One thing though is my drill press does not go down low enough in rpms for cutting metal. Makes for a tougher job.
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Post by Cottontail Customs on Apr 10, 2015 17:47:28 GMT
A jewelers saw is great for something like this
-Josh
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Post by chrisperoni on Apr 10, 2015 18:19:15 GMT
True true.
I have a good jewelers saw and swiss blades, I cut the nakago ana with it. Quality blades are most important imo when using a jewelers saw. But it would have taken a loooong time to saw the circumference of .25" copper. Instead I used my angle grinder to get close to round after the drill and hacksaw. Then disc sander to the line.
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Post by DigsFossils-n-Knives on Apr 10, 2015 18:20:21 GMT
I should look for those for next time. I have about a dozen mild steel plates that I want to cut tsuba blanks from and that would make it much easier. Not too expensive either - about the same cost as a basic metal cutting bandsaw blade. One thing though is my drill press does not go down low enough in rpms for cutting metal. Makes for a tougher job. You can attach them to a regular pistol grip drill. I would not recommend this for a thick or hard steel but it would be easy work for copper. I used to do it this way before I bought a drill press. Be careful not to twist your wrists when the cup binds in the steel. BTW: My drill press has a minimum speed 300 RPMs and it works fine and they last a long time. Use a cutting oil like WD-40 to reduce the heat and wear. Ignore the max 95 RPMs from the vendor.
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Post by chrisperoni on Apr 10, 2015 18:28:27 GMT
Everybody has different tools and techniques but the bottom line is figuring out a way to make it happen. We don't all have a fully blown machine shop or forge with all the bells and whistles...that's for sure. THIS. I don't buy into the whole "traditional way or nothing at all" thinking. Not that I don't respect it, but my view is that if you have the will and you can find a way then go for it.
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Post by chrisperoni on Apr 10, 2015 21:47:09 GMT
I should look for those for next time. I have about a dozen mild steel plates that I want to cut tsuba blanks from and that would make it much easier. Not too expensive either - about the same cost as a basic metal cutting bandsaw blade. One thing though is my drill press does not go down low enough in rpms for cutting metal. Makes for a tougher job. You can attach them to a regular pistol grip drill. I would not recommend this for a thick or hard steel but it would be easy work for copper. I used to do it this way before I bought a drill press. Be careful not to twist your wrists when the cup binds in the steel. BTW: My drill press has a minimum speed 300 RPMs and it works fine and they last a long time. Use a cutting oil like WD-40 to reduce the heat and wear. Ignore the max 95 RPMs from the vendor. How do you think they would do for 1/4" mild steel? Would you figure that is too thick?
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Post by DigsFossils-n-Knives on Apr 10, 2015 21:54:14 GMT
It will cut through in about 5 minutes (if you know how to cut with them). Plus you'll have nice center hole.
The trick is watch the chips as you cut. You need the right amount of pressure so the saw cuts little tiny flakes. If you are only making super fine dust then you're doing something wrong or your blade it too dull or your steel too hard.
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Post by DigsFossils-n-Knives on Apr 10, 2015 21:55:40 GMT
Oh, the disk you end with is smaller than the size of the hole saw (rough example, a 3" hole saw gets you a <2 7/8" disk)
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Post by chrisperoni on Apr 10, 2015 22:11:43 GMT
Tsuba is ready now. Used a diamond tip dremel bit and needle files for the ana. Wet sanded the flats up to 1k but it still has the heavier scratches from the initial belt sanding at the outer edges. I like how the larger scratches remain at the lip - helps give it contrast (besides I'm too lazy to take enough time to get rid of them all). The 1k scratch pattern reminds me of using a scotchbrite pad because I sanded in a circular motion. Buffed it with Mothers hence the mirror shine. I used just 2k around the edge to hit the high spots for contrast again. It's shiny and smooth and I like it. Seppa next - using 1/8" brass for them
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Post by Bryan Heff on Apr 10, 2015 22:19:25 GMT
That looks great!
How did You get that lip sort of deal around the edge.? Trying to figure this action out! Awesome.
Edit, never mind...you mentioned you hammered it. Fantastic! Loving this Chris.
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Post by chrisperoni on Apr 10, 2015 22:43:11 GMT
That looks great! How did You get that lip sort of deal around the edge.? Trying to figure this action out! Awesome. Edit, never mind...you mentioned you hammered it. Fantastic! Loving this Chris. From a tsuba making post a few years ago, and I feel like Sanmarc also mentioned somewhere how to do it. Use a piece of hardwood and cut a curved groove into it just a bit wider than the tsuba. I cut mine with the edge of my angle grinder; cut into a 6" or so block of wood and cut about 3" across with the deepest part not even 1/2" in, then clamped the block in my bench vise. Tsuba slides in edgeways and stays in place more or less. This way I can hammer the edge without deforming the opposite side and easily turn the tsuba as I go around. I'm sure you can be pretty fast and loose with how you make this wood block thingy.
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Post by aussie-rabbit on Apr 11, 2015 16:15:38 GMT
I should look for those for next time. I have about a dozen mild steel plates that I want to cut tsuba blanks from and that would make it much easier. Not too expensive either - about the same cost as a basic metal cutting bandsaw blade. One thing though is my drill press does not go down low enough in rpms for cutting metal. Makes for a tougher job. Depending on the motor type you can get quite simple vari-speed controllers for your drill press, harder for induction motors but available.
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Post by chrisperoni on Apr 11, 2015 17:58:46 GMT
how do I tell what kind of motor I have?
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Post by skane on Apr 11, 2015 18:51:36 GMT
Great looking project! This makes me want to try making an awabi style tsuba (ala Ogami Itto, Lone Wolf and Cub movies).
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