My Filipino pinuti developed rust spots. The most likely cause is storage in leather sheath (although I have many other blades stored the same way, this is the only one that has done this) and living on Vancouver Island. Therefore, I decided to make a wooden storage sheath for it, a "shirasaya" if you will.
The choice of oak (being the only available 1/4" stock in HD at the time) was not a particularly good one. I did some trial carving on it and found it very difficult. I then proceeded to rout out the two halves in the rough shape of the blade and finish off with some chiseling and finally sanding and a touch up with files when the thing was still too tight after gluing.
The result is here: Pinuti and "shirasaya" on Flickr - Photo Sharing! Sword in its sheath on Flickr - Photo Sharing!
It was better than I expected, the sword fit is just right. However, I was wondering if I could have done even better. For instance, getting the right shape of the cavity (a narrow wedge): "Shirasaya" opening on Flickr - Photo Sharing!
may have been easier if I glued temporarily a 1/16" thick strip to one of the halves and then routed it out just a smidgen over 1/16" - one side would have been full thickness, the other approaching zero.
The one problem I was struggling with was matching the two halves while routing: The two have to be mirror images of each other and there is opening only on one end, the other end is blind. In the end it does not matter too much as the whole thing got sanded down, but just as well that nobody can see inside the finished sheath
Does anyone have a clever way of doing this right? I am thinking of trying this again sometime in future for some of my other blades (and maybe adding some fittings etc.)
I did think of making a template but I suspect it would have taken me longer than making the sheath itself