How to Customize Your Own Samurai Sword
Samurai swords come in a variety of shapes and sizes, from the small and relatively straight to to the large, curved O-dachi nicknamed the "horse killing" sword. Fittings such as the tsuba (guard) and menuki (grip decoration) can be removed and replaced to customize a sword. The tsuka-ito (handle wrap) can be replaced with a different color cord or even with a leather wrap and the same (rayskin) underlayment may also be changed to a color that will complement the new tsuka-ito color. The saya (scabbard) may be customized with a new ito (cord) and by painting.
Things You'll Need
- Mekuginuki (brass hammer with punch)
- Hammer (brass or wood)
- Splint (bamboo,hardwood or steel)
- Rag or towel
- Soft wood block
Instructions
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1
Locate the mekugi (pegs) that hold the tsuka (handle) to the nakago (tang). The mekugi will have a big end and a small end. Lay the sword with the big end of the mekugi facing down and drive the mekugi through the tsuka and out of the bottom side. Inspect the mekugi for damage and replace with good, hard bamboo mekugi if the old ones are deformed or are of soft wood or buffalo horn.
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2
Remove the sword from the saya. Lay the sword down with the hole in the tsuba facing up and wrap the towel around the blade close to the tsuba. Lay the splint along the blade and insert the end of the splint into the hole in the tsuba and allow the shoulder of the splint to bear on the tsuba and seppa (spacer). Gently tap the splint with the hammer until the tsuka, tsuba and habaki (collar) loosen on the tang. Slide all fittings off the nakago. The blade is now naked and may be reassembled using the new custom parts.
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3
Hold the blade upright with the point down on a safe surface such as the wooden block and slide the seppa, habaki and tsuba onto the nakago. Push these fittings as far as practicable by hand onto the nakago and follow with the tsuka. Invert the blade assembly while holding the fittings on and gently tap the kashira (buttcap) against the soft wood block until the tsuka tightens up all the other fittings and the holes for the mekugi align. Lay the sword down and drive the mekugi into the peg holes to fasten it all back together.
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Tips & Warnings
Clean, polish and oil the blade when you are done to remove any contaminants and prevent corrosion.
Insure that the sword is "traditionally built" and meant to be disassembled. Decorative, or wall-hanger swords are typically not built this way and permanent damage may occur if you try to take it apart. There are no fittings that can be used to customize a decorative sword. If the sword is classified as shinken (real sword) be very careful while handling it. This is considered to be "live steel" and may cause grievous bodily injury if mishandled. Never work on an unsheathed sword with the edge toward you and never sheathe a sword with the edge toward you. Tsuka-ito should never be unwrapped by a non-professional. This is a specialized skill and will be a can of worms for the layman. If new tsuka-ito is desired, the sword should be sent back to the manufacturer or a sword shop to be rewrapped or to have a custom menuki installed.
