Skill Study: Japanese Metal Inlay

Inspired by the varied and numerous tsubas (Japanese sword guard) in collections world-wide, I spent some time learning the basic techniques used to make them.

An extensive site regarding tsubas

Starting with a hunk of mild steel and yellow brass, I sketched out a skull onto the brass and got to sawing....by hand. Considering the brass was 1/4" thick, this part went better than expected. I managed to get the entire shape cut without breaking a blade.

I filed out the profile of the skull until it was a little smaller than what I wanted the final to be, and transferred this shape to the steel. I first began to remove material with my foredom (rotary tool), but honestly hand chisels worked much better and quicker. Being mild steel I was able to carve out the spot for the brass skull as if I were carving a fruit wood.

  

Next came the process of fine-fitting the brass into the steel. I undercut the steel a bit and refined the brass more until with slight force, both mated perfectly. This was an incredible feeling. To set the brass, I hammered evenly around the edges in a circular pattern, forcing the brass down into the undercut in the steel. Once it was in tightly with no hope of ever coming out, I polished the top of the brass and re-drew my pattern for the skull. 

Now it was just a matter of carving out the brass until I had a skull. Carving metal is loads easier than any wood. There's no grain and if you mess up a little you can sometimes hammer and file it so the mistake is unnoticeable. I ended up making a lot of tools for this project: fine gravers, burnishers, and blunt punch chisel things (essentially leatherwork shaders, but for steel). I added a small cherry blossom above the skull to balance the piece and continued to refine the details.

A sprinkling of OCD, some swearing, and careful hand polishing...then I was done.

Thank you for reading!
~Copperrein

Cherokee Tomahawk

   

Cherokee tomahawk I made for one of the chiefs of the Cherokee Nation in North Carolina. Traditionally forged head of wrought iron with forge welded steel bit or cutting edge. The head is engraved and etched with traditional Cherokee motifs including the Cherokee Star. The handle is quilt figure Rock Maple and is inlayed with Red Brass bands and Silver "winds" and Dogwood flowers (State flower of North Carolina)

Pipe Tomahawk with Fine Silver Accents

A fairly simple object in design, as a whole this pipe tomahawk feels and looks harmonious. This will always be one of my favorites that I have made.

The head is hand-forged from 50cal gun barrel The handle is curly maple, finished with my ever-evolving experiment with violin finishes from the past. I've rolled fine silver into sheets, then formed and soldered them to construct the mouthpiece and inlaid cross.

Originally these would have been made by white Americans and Europeans to trade with native Americans. The first examples come from England, but the practice of making these is said to have been taken to a new level of art when apprentice gunsmiths began crafting pipe tomahawks as a means to hone their skills.

~Copperrein

Burgonet Helmet

A past armouring project; recreating a munition grade Burgonet helmet of the type brought to the early shores of America. Currently part of the living history at Plimoth Plantation National Park

American Scandanavian Fusion Knife

I needed a mental break from making trade tomahawks. While I do enjoy making the 'hawks, I missed the lines and process of the knife. This little Frankenstein is the result.

The blade is high carbon 1095, forged, shaped, heat treated, and tempered. A blister finish graces the blade, giving it the slightest texture which catches the light nicely. The knife features a nice fat tang running to within 1/2" of the end of the handle. The handle is a stacked affair comprised of stabilized buckeye burl in subdued earth tones, white tail antler (stabilized), and brass. All components have been polished to a high satin finish before receiving a few coats of poly. The blade has been dressed with Renaissance Wax.

The sheath is oak-tanned deer. All parts of the sheath have been distressed, textured, dyed, fattened, stitched, and polished by hand, by yours truly. The brass concho can be etched with a design of your choosing, or left plain (I envision the owner's initials here). The tassels are hand-cut sheepskin.

The only mass produced hardware I've used was for the back of the concho where I hacked apart a screw-back rivet and soldered the threaded bits on.

Blade: 4.25"
Overall: 9"

Thank you for browsing,
Copperrein

Price upon request.

US Navy Commemorative Tomahawk

US Navy Commemorative Tomahawk I made for the CMSA Atlantic, an exact copy of their until logo. Cast Bronze blade inlayed with brass Tomahawk Cruise Missile, diver salvaged oak handle with raw hide and feathers.

Handmade Banjo with copper tone ring

  Banjo I made in 2009. Maple neck with bent Ash pot and copper tone ring

Flint lock rifle

   I made this .54 caliber flint lock rifle back in 2010. In my personal collection

18th century Gentleman's Square

   This is a layout square I made in the style of gentleman's tools of the 18th century. Wrought iron leg hand forged and filed, with a shear steel blade 

Military Tomahawk 50th Anniversary

   This commemorative military tomahawk I made for the 50th anniversary of the 2nd US Division protecting the DMZ on the Korea  Peninsula. It is on permanent display at the Museum of US Armed Forces, Seoul South Korea 

1830s Eagle Head Sword

   This project was a restoration of an original 1830s Eagle Head sword. These swords are a quintessential American style from the Federalist Period in the beginning of the 19th century. Carried from the War of 1812 and into the Mexican-American War, a few were personal carries during the American Civil War.
   It was a rewarding project to bring this American treasure back to life! 

"Masters Study" 16th century Left-hand Dagger

   This project was one of what I term my "master studies" - where I push myself in techniques seen in originals, but not in contemporary craft. This is a 16th century German left-hand dagger that would have been paired with a rapier or arming sword during the period. As a secondary weapon their main use was parrying the opponents attacks, while giving the wielder a chance at attack themselves.

   The stout blade is stiffened by double fullers (blood grooves) and a heavy triangular center rib to allow the blade to penetrate armour or heavy clothing. The blade is pierced through the webs of the fullers in the High Gothic German style. Large swept quilions and side ring protect the twisted iron wire wrapped spiral fluted handle and scent stopper pommel. The scabbard is hand formed and sewn leather dyed black with traditional chemicals. Silver mount and arming style frog.
   This project took over 400 hours of work and has stayed in my personal collection.

A new path, a beginning

Welcome to the new blog History Through the Hammer's Eye!
A continuation of Iron John's and Copperrein's artwork, projects, and life; through a connection to the past.