![]() When I say "slid" what I really mean is "used a rubber mallet to pound it into place". First I slid the guard down and glued it in place. This step is pretty much just a matter of slathering everything with wood glue and clamping it together. After I was satisfied I did a test fit on the sword blank. I used a straight saw and a coping saw to get the basic shape, then moved to a belt sander, and then finished by going over it with a file. After I was happy with the inside I cut the shape out of the block. Then I used a small file to curve the inside edge down so it would rest against the rounded part of the sword blank. I didn't want it to be able to slide down the blade. Notice that I only drilled the hole wide enough for the pommel to fit through. Once the glue was cured I drilled out the slot that the sword would fit into. I glued the two boards together with wood glue and clamped them tightly until it cured. For the guard I drew up a pattern for the top and then for the side and transferred it to the wood. I had to put two boards together to get the right thickness. Then I cut it off and gave it a good sanding. Then I cut through the middle splitting it into two thinner pommels. I cut out the sides but left it attached to the board. I traced the pommel from the main sword blank onto the other wood. So I'm using that since it will be easier to work with. You can use any excess you trim off the sword for this part, but the board I'm using is a very hard wood and I had some other scrap that was much softer.
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