How to Repair a Samurai Sword

Easily among the most respected and efficient bladed weapons ever designed, the katana (or samurai sword) is a frequent item in Japanese martial arts traditions. Prone to occasional rust spots as well as nicks, notches and other damages, the Japanese sword is surprisingly resilient and remains a comparable weapon and cutting tool. With some minor supplies and attentiveness, you can retain the beauty of your sword while ensuring that it remains a collector's item for years to come.

Things You'll Need

• Katana
• Work gloves
• Fine steel wool cloth or gun/reel cloth
• Nev-R-Dull rust remover or similar chemical cleaner
• Japanese Choji Date Oil or other sword oil
• Rag
• Whetstone with fine grain
• Work desk
• Screwdriver (optional)
• Paint (optional)

Instructions

1. Assemble your work desk in an area of sufficient lighting with your katana, rag, cloth, oil and chemicals within reaching distance. Ensure a safe working environment by keeping children or animals away from your working surface.

2. Put on your gloves and carefully remove your katana from its scabbard, making certain that you do not touch the blade with your bare hands (this leaves corrosive oils on the blade which cause damage over time). Place the blade near you where you can clearly see the blade.

3. Inspect the blade for any immediately visible pits, nicks, notches or rust spots. Take note of any rust on the blade and reposition the sword so that these areas face you and are within close range.

4. Open the Nev-R-Dull chemical cleaner package (available at most automotive stores) and remove a small square of the cotton cleaning material. Apply the chemical cleaner to specific rust spots while avoiding chipped or clean areas of the blade in order to avoid discoloring. Rub firmly before disposing of the cleaner and wipe thoroughly with the rag until the rust spot has evaporated. Repeat this step with all rusted parts of the sword.

5. Reposition the blade so that the sharp edge points upward and gently run a clean gloved finger across the blade at an angle. Note any notches, nicks or indentions in the blade's edge.

6. Hold the blade steady with one gloved hand and, with your free hand, gently apply the fine-grain whetstone to nicks and notches in the blade. Use smooth, long strokes until the edges of each notch has been effectively removed.

7. Open the oil container and apply six drops of sword oil along each side of the blade while rubbing the steel cloth along the katana. Carefully rub the sword blade from one end to the next until it is completely smoothed by oil.

8. Assess the condition of the handle or "tsuba" of the sword. Retie any parts of cloth that have become loose and tighten bolts in the tang where necessary, using a screwdriver with the appropriate head. If desired, touch up parts of paint that may have been damaged in the handle, or polish the metal "tsuka" or handle guard with oil, for a nice sheen.

9. Return the katana to its scabbard and store in a very dry area. Check the condition of your samurai sword at least once every three months and repeat the process if you encounter any additional rust spots.

Tips & Warnings

• For severely damaged swords wherein a crack has formed in the blade and has penetrated the "hama" or temper line, only a professional reforming of the blade will make the necessary repair. In this case, search online for a sword smith service such as that provided by Nihonzashi.

• Always handle your blade carefully. Always store in a safe area away from children and animals.

References

• The Iaido Journal: Katana First Aid Tips
• Nihonzashi Sword Sharpening and Polishing

Resources

• Samurai Sword Mekugi Repair: A Video