Broken Saya Repair?

[Ffffrosty]

Hi All,

 

Sadly EMS killed this saya.

 

Any thoughts on whether this can be repaired and who I should contact for repair?

 

Here are pics...

 

Thanks,

Mark

[Klop]

Hi Mark,

 

That's a shame...

 

But the good news; to me it looks solvable.

You could do it yourself if you know how to handle tools;

 

take a new flat piece of buffalo horn (for example http://www.namikawa-ltd.co.jp/cgi-bin/i ... te=24&no=1 ) and cut out the hole that goes over the wooden guchi in which the blade enters. That is a delicate job, first step is a jigsaw (manual of course) to cut an undersized hole and than refine it with a set of small files (locksmith files).

Frequent fitting ensures the right size.

 

Keep the horn piece oversized in relation to the outside of the saya. When it is glued in place you work this access down to the right level all around ( protect the laquer next to it with tape) with small file, sandpaper up to #1000 or 2000 and polish (dremel miniature buffer is great for this). Take care not to round of the edges, you want the lines of the saya to continue straight to the seppa!

 

When the new horn koiguchi is done maybe the crack on the seem closes to an acceptable level automatically, otherwise some touching up with laquer or paint should do the trick, copying the structure if possible. I myself would not consider relaquering the whole piece or just the upper section, better some minor damage than complete loss of the original coating.

 

Unfortunately I don't know anybody who can do this for you if you can't do it yourself.

 

 

A remark about the cause and prevention; this damage looks like the blade was pushed in so far that the habaki split the mouth. In other words, the mouth is just a bit too tight to accept the habaki well, if the new situation is just as tight it might happen again. Maybe this has to do with different temperature and moisture, what was a good tight fit in Japan might become a too tight where you are because of shrinking wood. Adjusting the fit slightly might be the answer - by file, not sandpaper because of lost grains vs polish!

 

 

Good luck,

Eric

[Ffffrosty]

Hi Eric.

 

Thanks this seems like good advice.

 

It is cracked all the way through the saya on both sides, rather than just surface deep.

 

So, it will probably need wood glue and clamps.

 

The damage was actually most likely caused by a large package being dropped on the tsuka which popped the mouth of the saya open.

 

Does anyone know if Moses does repairs like this?

 

Thanks,

Mark

[Alan Morton]

Hi Eric,

I have had lacquer restoration work done by Micheal Cummins who is studying lacquer work

in Japan. I was more than pleased with work done and the price.His email is me.cummins@gmail.com

he also arranges polishing and handle binding.

Regards Alan.

[Grey Doffin]

You could also try John Tirado or Brian tschernega, if you can find contact information; I bet at least one of them can do this and would do a great job.

Do not try to fix the cracks yourself with glue and clamps; leave it to the pros. In the mean time here's a temp repair that will do no damage. Wrap a strip of paper around the top of the saya and then tightly wrap the paper with tape. Masking tape works well for this. The paper will keep all adhesive away from the lacquer.

Grey

[Ffffrosty]

Thanks for the leads... I'll reach out to them to see if they can help.

 

Any leads on anyone who makes new saya that are truly breathtaking?