Problems assembling Tsuka to Sori; soliciting help and or tips/tricks/vendors

[Jason Pavicic]

Long story short, I purchased a Nihonto back in May while visiting Japan from Tozando in Kyoto. It has a proper certificate, from late Edo period. It took 4 months to get here, Saya was damaged etc. Finally, I have everything and all is well, ready to display.

 

Unfortunately, while trying to put the Nihonto back to together, the Mekugi pin/holes do not line up. I've watched countless YouTubes and tried mixing the order of parts, no luck. Really don't want to start banging on it.

 

First the 3 pictures show the following:

1. Both Seppas installed, Mekugi goes in at severe angle and stops. Holes are off.
2. Removed bottom Seppa, goes in a little better, but still stops with less angle. Holes are still off.
3. Removed both Seppas, everything lines and Mekugi goes in cleanly, as expected IF Seppas were in place.

 

Observations:

• If I had various Mekugi pins (size and or taper) to try, it might work even at the severe angle for all parts.
• In the last pic, I shows the Tang compared to Tsuka. Here you can see an additional Mekugi hole not being used, and the Tsuka is much longer than the Tang (is that normal?) Sori is 33" long.
• My gut, the Nihonto is legit, for sure. However, this is not the original: Tsuba, Seppas, Habaki and Tsuka for this Sori/Nihonto. When I selected this Nihonto, it was never full assembled. Sori and Tsuka were displayed separately...

 

Questions to the forum:

1. Any tips or tricks to try, to get it to work? Sent same pics to Tozando, they're consulting their Craftsman for options.
2. Any US based folks who specialize in this type of work?
   1. Thinking it would be just easier to freshen up the look and have a custom Tsuba, Seppas, Habaki and Tsuka built to match the holes on theTang?
3. Other recommendations welcomed.

 

Thank you in advance for taking time a look at this issue.

 

Respectfully,

 

Jason

[Brian]

Have a new habaki made that is 1.5-2 mm shorter?

[Matsunoki]

Buy a thinner tsuba or reduce the length of the habaki by maybe 2-3mm (tricky if it’s a good foiled ptype) Just quick thoughts. I’d go thinner tsuba……much easier.

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