Forming Metal Saya

[Mark S.]

I’ll apologize up front if asked or discussed before, but is there a thread or reference that discusses how the metal saya on gunto mounts were formed to match individual swords?  Taking into account differences in length, sori (especially when older blades were pressed into service), wood inserts, etc, I’m just wondering if wooden blanks were made and the metal saya fitted around it?  Interested in the process.
 

This question popped into my head looking at the recent straight blade gunto and then thinking about the mass quantity and wide variety of metal saya needed that individually had to be ‘custom fit’, especially when it needed to be done quickly due to war-time expediency needs.  
 

And as Gunto are not my main area of study, I’m sorry if this is readily available info… I just don’t have much reference materials regarding Gunto.
 

Thanks,

Mark

[Kiipu]

Mark, unable to answer your question; but, I can provide a link to the type of machinery involved in scabbard production.

Scabbard Kaizen Projects

[PNSSHOGUN]

Interesting that Zohei-To blades were adjusted to match the pre-made Saya dimensions.

 

[Mark S.]

Excellent information so far… thank you!