Buffing - Ahh, the wondrous Buffing Wheel (otherwise known as the "Wheel of Misfortune," because it gets pieces hotter than any other machine in the Shoppe aside from the furnace or brazing torch). Buffing compound (called Tripoli) is comprised of mildly abrasive silica powder in a thick paste, so it has a tendency to collect in deep undercuts and crevices, but I use a water soluable brand that cleans up easily. (Even though some gunk here and there provides an interesting "antiquing" effect.)
Fitting - Wow...I FINALLY get to assemble the damned piece. At this stage, all the pieces come together in the same tray and can be fitted up. We measure each piece to assure a decent balance and then grind the blade to fit the hilt, careful to not overheat the steel and thus weaken the temper.
The tangs are threaded a nice meaty 1/4" by 20 for the pommel and any etching, engraving or sharpening would happen at this point.
Handle Turning - Eventually, everybody must get lathed. Choosing from our small yet funky collection of regional & exotic hard woods, we cut & measure out blocks with an eye for unusual grain patterns or colors. All the handle shaping, sanding & polishing is done right on the lathe. Finally, the handle is drilled out and fitted onto the tang and with the pommel added, the piece is finally DONE. Whew!
Some boneheads have commented that I use table legs for my handles, to which I often reply with a vivid description of my blowing the Technicolor snot from my nose after turning several ebony, cocobola & vermilion handles. That tends to shut them up.
|
Method to the Madness 
