Scabbards

[Sir Brian]

Maybe not so much as a full blown 'How To' but more of a confirmation of some of the techniques mentioned in the link I originally posted.

[Sir Brian]

A couple of big pots full of boiling water in the bathtub for an hour was sufficient to achieve this kind of bending. Instead of a coat of oil to protect the sword blade while sandwiched between two wet boards I smeared it with some petroleum jelly which worked very well and cleaned up nicely. (Your sword is safe and sound Sir Edward! Thanks again for the loan!) 

Next step was to glue the slats together but I definitely need more clamps. Here is approximately $23.00 worth and I could have used a few more. - No such thing as too many clamps! I'll find out how well the wood glue does in a day or so.

Next up is cutting off the excess wood!
- Yikes that just sounds like a Lorena Bobbitt  reference!

[Sir William]

That's coming along nicely, Sir Brian!  LOL @ Lorena Bobbitt

Now there's a sobering thought.

[Sir Wolf]

could have also covered the sword in saran-wrap?

[Sir Patrick]

On Gaffer's site he cut the scabbard to shape prior to the bending/glue up. I never could figure out how he got that hold. Your method of glue first cut later makes more sense.

[Sir Brian]

could have also covered the sword in saran-wrap?

That along with using cord to wrap it is a viable alternative but the clamps are easily set and adjusted.

On Gaffer's site he cut the scabbard to shape prior to the bending/glue up. I never could figure out how he got that hold. Your method of glue first cut later makes more sense.

I'm sure his method works best for him since he's probably made a bunch of scabbards, mine seems best suited for a novice like me!

[Bernarr]

Lookin good!

[Sir Wolf]

could have also covered the sword in saran-wrap?

That along with using cord to wrap it is a viable alternative but the clamps are easily set and adjusted.

On Gaffer's site he cut the scabbard to shape prior to the bending/glue up. I never could figure out how he got that hold. Your method of glue first cut later makes more sense.

I'm sure his method works best for him since he's probably made a bunch of scabbards, mine seems best suited for a novice like me!

nooooo i meant wrap the sword in the wrap while the wood formed around it to keep the damp wood off the blade

[Sir Brian]

Doh!
ich verstehe!

Yeah that would work as well but then you wouldn't have the wonderful anxiety of slicing yourself on a sharp blade!

[Sir James A]

That's coming along nicely, Sir Brian. Can't wait to see the finished product!

[Lord Dane]

Wow, that is a beautiful piece, Brian...I can't wait to see the end result.  Where'd you get it, if you don't mind me asking?

"End" result as in scabbard "tip"?? No puns intended, right?? lol

[Sir William]

Umm...no, not as I intended when I wrote that.

[Sir Brian]

UPDATE:

I am now on my third attempt at the wood core.

The first one did not have enough bend to accommodate the blade’s diamond geometry.

The second attempt involved much more prep by sanding out a channel along the centerline of the core where the blade would slide. This seemed to be successful however for some inexplicable reason during the final drying stages the wood warped out of true and would not allow the blade to seat fully.

Now I am working on a third attempt with probably even more preparatory work. – Sigh really starting to appreciate why the high cost for custom scabbards! 

[Sir Edward]

Yeah, this is why I don't mind paying someone who knows what they're doing. But it's also a learning process. If you make scabbards every week, I'm sure it gets a lot easier.

[Sir William]

It is a lucrative venture, once you get your technique down pat, or so I'm told.  Judging by the price of even entry level scabbards- very lucrative.  Also time consuming...