German hunting trousse, part XIII

After the trouble with stretching the facing over the side pockets on the last sheath, I contacted Tandy Leather about what kind of hide would work better for this purpose.  They recommended either a milled shoulder or sheepskin, with the caveat that neither of these would firm up when wet-molded.  At the time I went to place my order, the sheepskin was sold out, so I ordered the milled shoulder.  In the meantime I made an entire new core and side pockets.  I attached the side pockets this time with pitch glue, though that may have been a poor choice because it's very hard and brittle.  Otherwise, I proceeded in the same manner as before, up through the initial wet molding of the facing.

The milled shoulder did indeed stretch more, leaving little slack above the side pockets.  However, the same quality also allowed it to mold to every uneven spot on the side pockets, giving the scabbard an overall lumpy appearance.

In preparation for the final application, I shaved down the lumpiest parts somewhat.

Because the folks at Tandy expected the milled leather to remain soft after molding, which it did, they suggested installing an extra belt loop under the facing.  I used a short strip of thin but firm veg-tan with the ends and edges (outside of the middle section that was to actually go over a belt) tapered down to reduce the appearance of unsightly ridges.  Since stitching would be at risk of damage from the blade and rivets would risk damage to the blade, and both would be difficult to achieve, I glued the belt loop with contact cement.

A 1-inch belt blank with burnished edges inserted under the wet facing and belt loop to ensure that it would remain open after molding.

Lesson learned, this time I  didn't use any glue; the facing is held on only by its own tight fit over the core.  I also didn't try to pre-lace the facing before the final fitting.

I finished with some Fiebings Pro Dye and a couple applications of acrylic Leather Sheen (my bottle of Resolene is missing).  I worked the dye and finish as far in as possible so as not to leave patches of undyed leather visible.

Current state of completion, with some Fiebings Pro Dye and a couple applications of acrylic Leather Sheen.  At this point the set is useable, provided I have a belt that can carry it.  I though it would be necessary to add a metal throat to prevent the pins on the knife and fork from marring the facing, but for whatever reason they actually stand off a few millimeters.  However, I haven't seen a 17th-century hunting trousse without scabbard fittings, which always seem to have been either silver or steel.  I will have to give careful consideration on how to make them, since steel would be the best choice in this case but I have never made steel fittings, and my attempts at soldering steel have been much less successful than brass.

The other issue at the moment is that it's been very difficult to sheathe and unsheathe the by-knife, at least the final inch of it, which is necessary to also be able to sheathe the cleaver.  I haven't oiled or waxed the leather yet; hopefully it'll be easier once that's done.

Another thing that went wrong in the intervening months is that minute amounts of red rust have appeared both on the blade (while I was molding the leather) and in crevices of the fittings, particularly where the nagel is set into its groove.  I applied Ospho with an Q-tip, and once it was well-dried, worked epoxy into the deep crevices, wiping off as much as possible from the more accessible surfaces before re-polishing them.  Time will tell whether these efforts provide effective protection.

German hunting trousse, part XII and the unexpected problem

I settled on glueing the fork pocket with the seam inward and not to include a plate over the side pockets.  Fitting the outer facing was tricky; it had to be stretched to fit smoothly over the side pockets without leaving a lot of slack sticking out the sides.  For this reason I wet-molded it first.

To try to keep the facing from crushing the side pockets, I inserted the knife and fork.  To keep the facing smooth above the pockets and prevent the protruding rivet heads from making marks in the damp leather, I placed some small brass plates.  The space between the top of the scabbard and top of the side pockets is almost exactly two inches.

To get the facing to mold as closely to the core as possible, I used most of a bag of binder clips.  These somehow seem to have stained the back with little black spots, possibly from exposed steel on the edges reacting with the veg-tan (similar to vinegaroon).

Once the facing was dry, I trimmed to down to the straightest, closest edges I could manage using a combination of an xActo chisel point and scissors.

It was while punching the stitch holes that I remembered to add the belt slits, which have to be done before stitching or I would risk damaging the inner layer while cutting them.  This method is, again, inspired by one used on the Bruegel messer.  If I'm going to add a metal throat and a hoop supporting the top of the pockets, it's necessary to add the slits between them.

My plan was to loosely stitch the outer layer, soak it, insert the core and tighten the stitches one by one.

It proceeded according to plan except that I could only manage a single whipstitch with the length of linen thread I'd cut.  The outer layer shrank nicely against the core.  The problem of the facing above the pockets being a bit too large remains, but while unsightly, it's not too bad for me to overlook on a first attempt.

The use of two brass plates had caused a visible line across the top of the facing during the initial wet molding, so this time I added a single two-inch plate.  This did seem to help.

Unfortunately, a new problem came up at the end:  It seems that some of the hide glue I added to fix the facing in place either soaked through the wet leather or got out at the seams and onto the facing.  The glue appears to have interfered with the absorption of the spirit dye, so that repeated brushings of dye failed to get rid of the patchy appearance.  Whether this problem can be solved at this point and how, I'm not sure.

German hunting trousse, part XI

I initially intended to make a box-style wooden scabbard core for the cleaver, but after examining how the Bruegel messer scabbard is constructed and contacting Tod's Workshop, I decided to see whether I could make a similar style here.

The messer scabbard is two layers of fairly thin veg-tan.  The inner layer is unstitched, while the outer layer has a flat Z-shaped double whipstitch, unlike the double running stitch I'm used to using that leaves a ridge down the back.  The double running stitch is used because it helps keep the stitching away from the blade so that it's harder for the blade's point to catch on the stitching when resheathing.  An unstitched layer obviates that risk entirely, but I don't know how they manage to mold the leather to the blade with no stitching holding it in place.

In any event, I felt the need for stitching in the core layer, but also to keep the point at least somewhat away from the stitches.  So after measuring and cutting the leather as usual, I trimmed it until it looked like it would just barely wrap around the blade and meet in the middle, then poked stitch holes at an angle so they came out the sides of the cut edges.  I stitched with size 40 linen thread and soaked the core with alcohol.  On the suggestion of Sword Buyers' Guide poster erichofprovence, I made the core and side pockets rough side out, in order to encourage better adhesion between them and the rough inner side of the facing layer when everything gets glued together.  Because it seemed like it was going to be on the loose side, I tried to make sure it dried more snugly by warming it gently over a heater to shrink it, letting it spend plenty of time off the blade, and not wrapping the blade with tape.

The side pocket for the carving knife offered no such easy solution.  The 2-3oz. leather is too thin to poke angled holes out the edges.  A normal butt stitch would leave the thread exposed to the knife point.  A normal side welt would add unwanted bulk, and a double running center seam would create a ridge that would either prevent the pocket from lying flat against the core (if it were on the back) or be visible through the facing (if it were on the front).  What I settled on was to mold the pocket so the seam ran along the blade's spine and slightly to one side and down, so that it's not threatened by the blade's point or edge and lies flat against the core.

An interesting thing to note is that the rosin varnish, even after drying in the sun and then ageing for almost two years, still gets sticky whenever alcohol gets on it.

The side pocket for the fork was simpler, and in fact I think it's better not being molded, so the leather doesn't shrink in such a way as to prevent the tines from sliding freely in and out.  I did add a very small, thin welt at the tip, but this doesn't seem to prevent the tines from sliding between the stitches if the fork is pushed in too far.  I don't think of this as a serious problem.

For the time being, I'm instead wondering whether to turn the fork pocket with its side seam inward or outward.  The cleaver blade being a relatively narrow one, the main scabbard doesn't leave room for the knife and fork pockets to sit separately like in most hunting trousses.  Instead, they'll need to overlap.  For me the next question is which way will cause less of an unsightly ridge and allow the facing to lie most smoothly.

A separate issue is whether to include a leather plate with a pair of slots for the knife and fork to pass through, covering the mouths of the side pockets.  Real hunting cleavers normally had a metal plate (the metal being whatever steel, brass or silver the rest of the scabbard mounts were made of, attached to a worked metal hoop that went around the entire scabbard, presumably to help prevent the mouths of the side pockets from being crushed) although I've seen one that appears to be made of either wood or leather, and absent the ability to weld, I may be forced to rely on leather.  However, there may not be room for a plate here at all.

All this relates to the question of how much metal hardware I'm putting on the scabbard; the Bruegel messer's scabbard, for comparison, has none at all, and although they're from slightly different time periods, I can't help but think of the messer and trousse as forming a matching set.  If I made a chape and throat for the cleaver, I'd feel compelled to make one for the messer as well.

German hunting trousse, part X

The cleaver came together much like the accessories:  scales oiled and varnished, allowed to cure in the sun, then glued and set with mild steel pins.  No process pics this time, it was too messy.

I accidentally left the scales out overnight in what I thought was an aluminum tray.  It turns out it was non-stainless steel.  Dew collected under the scales in the morning, causing the scales to swell, the oak tannin to react with the steel and create black stains on the undersides of the scales, and the surface of the tray to rust.  Also an animal pooped in the tray, though thankfully nowhere near the scales.  The warping resided after a few days indoors.

I had earlier found that when the accessories, whose scales were attached with pitch glue, were allowed to get too hot, the glue softened and exuded out of the seams.  I attached the cleaver's scales with epoxy and set the pins while it was still liquid.  This was not a good idea, as the epoxy got onto the scales and was very difficult to wipe off.  The finish is therefore duller than it should be.  In this regard, it may have been better to use pitch glue, which would cool and harden rapidly.

The hilt is not comfortable to hold thanks to the protruding washers, but perhaps this would make for a more secure grip, or historical washers may not have been as highly domed as the ones I used.  The pins required many little taps with a light ball peen hammer to tamp down the edges of the peens and prevent them from scratching the palm of my hand.

This project is far from over.  It will require a specialized scabbard with side pockets for the accessories and custom steel mountings, and possibly a belt, before it can be considered complete.

German hunting trousse, part IX

I next returned to working on the cleaver.  I've been putting it off for a long time because of technical challenges that I was unsure of how to deal with.

Firstly, a method of how to fabricate the side ring rivet and affix it in such a way that it wouldn't rotate in the rivet hole had long eluded me.  Many of the originals have spike-shaped extensions sticking up from the rings along the bolsters which I surmise were created by sophisticated forging techniques and incorporate extra pins.  Fat chance of me accomplishing anything like that.  However, not all of them are constructed this way, and I eventually came across a post on myArmoury by Lukas Mästle-Goer which shows an alternative method:  The side guard - in his case a shell Nagel for a Rugger, but it would work just as well with a Waidpraxe's ring - has a rectangular base that fits into a slot on the face of the bolster, locking it in position.

With this understanding, I drilled a 5/8-inch hole in a bar of mild steel, cut out the ring around it with an angle grinder, and ground and filed its shank down to a round cross section 3/16 inch thick.

The other problem was no more complicated but will take longer to explain:  Most hunting cleavers of the 17th century have a finger guard on the edge side of the blade that protrudes out past the blade shoulder.  This seems to have been created in one of two ways:  Either the bolsters are forged as a single piece that semi-encloses the tang, with the two bolsters held together by the finger guard itself, or they're made in two pieces and the tang also features a protrusion that they're sandwiched on either side of.

Because I can't weld and the Crazy Crow blade has no such extension, my first attempt to deal with the problem was to create a pair of bolsters with protruding finger guards, soldered together by a small piece of filler steel.  However, this proved unfeasible.  The filler piece was a hair too thin and the tang wouldn't fit into the guard.  I tried grinding out the inside, but the solder wasn't strong enough to stand up to the vibrations and the guard fell apart.  After re-soldering and re-grinding several times and getting nowhere, I put the whole thing on hold.

Again, myArmoury came to the rescue.  At a later date, I found a post by Radovan Geist of a knife that looked a lot like the one I'm working on, although it is intended as a Bauerwehr (thus again a solid shell Nagel instead of a ring).  It even had a little un-beveled section of blade shoulder just like the Crazy Crow blade's ricasso, which Radovan used as the support for the bolsters.  Looking through my collection of hunting cleaver photos, I realized that a handful looked quite similar with small finger guards that didn't protrude past the edge of the blade.  This was the solution.  (I also copied his idea of adding a thinner pin hole to the blade shoulder so that the bolsters could be pinned there as well.)

Starting fresh, I cut two new pieces of mild steel in approximately the shape required.  Another problem soon arose:  The part of the blade that transitions from the tang to the ricasso becomes thinner, and while the transition is more-or-less flat on one face, it's curved on the other.  This meant that while one bolster could just sit as it was and be pretty much flush with the blade, the other needed to be ground on the inside to match the curve; otherwise, it would teeter across the tang's surface, leaving a large gap on one edge or another.

 

The bolster partly through shaping.  I managed to get it not quite so bad after a few more passes of the angle grinder's flap disc, but perfection eludes me.  In this project I won't feel so bad about using a modern epoxy to fill the gaps..

Once that was done, getting the profile perfect was simply a matter of glueing, drilling, and grinding the edges flush with the tang.

After that, the bolsters could be detached and rough-shaped.  Adding the slot for the ring was another tricky step:  Unwilling to risk mayhem with the aggressive angle grinder, I instead used my Dremel with a fairly small flat stone grinding disc.  This took longer but I believe reduced the chance of the slot coming out crooked.  I finished it with coarse files.

Next I added some decorative grooves freehand with needle files, then polished everything up.  Finally, it was time to peen the pins and rivet.

I epoxied first, then set the smaller pins - a cut section of 1/8-inch common nail as used throughout this project, and an annealed section of thinner finishing nail in the shoulder area.  Then I ground and polished out the dings.

 

I set the ring rivet last, after annealing, re-polishing, and shortening the shank.  To prevent the ring from being marred, I put the 5/8-inch drill bit through it and had it rest on two steel blocks with the ring between them.  The bit supported the ring and prevented it from popping out as the shank was peened.  Then I once again ground and polished the peen to be less protrusive and visible.

 

The cleaver with rough-cut oak scales and washers.  I'll be getting them closer to their finished shape and might start the scabbard over the next few months, but this is the last update I'll be sharing on the cleaver until spring, when the weather warms up enough to varnish the scales.