Professional Documents
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step 1Overview
Contents: Basic dimensions Making the Boken Terminology Notes & Cautions Dedication I suggest that you borrow or buy a boken before you start, so you can get the feel and see the details of what you are making. It will also help you set up the curvature of the one you create. Hopefully you are already training with one at some level, so you have an understanding of the balance it should have. Ganbate kudasai (Japanese for good luck)
step 4Gluing it up
Use an existing boken to establish the shape that you will bend the two pieces of wood over. You want to get a reasonably close match on the inside curves. Clamp the center first, then work your way outwards. Clamp directly over all the support sticks, and then at the ends. Fill in clamps afterwards. Let the set-up dry for about 4 hours. Wipe off what glue you can. Once dry, scrape off the glue that has pushed out.
step 5Planing
Use a planer or jointer to straighten one side of the boken. This one had a 1/8 inch bow in the center. After one side is fairly straight, rip it down to about 1-1/4 inch, cutting off the rough side. Turn it around and rip the other side, down to 1-1/8 inch. Plane or sand the boken down to 1 inch to get the sides smooth. I use a planer instead of sanding whenever possible (saves work and doesnt make a lot of dust)
step 6Routing
Route the boken on all four corners with a 1/2 inch round-over bit. Cross-cut the handle end to clean it up. Mark where the tsuba will sit (10 inches). Route the 45 degree chamfers, which become the backside of the blade. Route close to where the tsuba is marked, but not into it, you need to complete it with a chisel (sharpen it beforehand). Cross-cut the blade end to length (40 inches)
The boken made here is for actual practice, so I chose the hardest wood I had. It is very satisfying to use weapons in practice that I have made myself. Two colors of wood make the boken look unique. I have not found anywhere you can buy one like this. Use only sharp bits, blades and chisels. Burn marks and gouges will show. I suggest you make two and keep the best one. There is very little wood used in a boken, and it saves you a lot of pain if you make a mistake. Making two is almost the same effort as making one. If they both turn out, give one away. Use safety equipment: eye protection, ear protection, guards, push-sticks, brain. Do not do anything you think may be hazardous its not worth it. Disclaimer: I assume no liability if you purse this project. No information here is intended to override the safety instructions for your equipment or your common sense.
step 11Dedication
I dedicate this to Master Eric Johnson, who has taught me the beginning steps of the bokken. He is the founder of the Tien Tae Jitsu martial arts system (www.tientaejitsu.com)