My first semester of college, I joined Alpha Phi Omega. My “big” (mentor) was a fellow Kingdom Hearts fan. It was customary for the “little” to give their big a gift after two semesters. Not having the means to make anything, I designed an APO-themed Keyblade, and presented her the blueprint. She liked it, but I would have liked to actually make something.
So over the summer, my family’s apple tree’s limbs were literally snapping off from the weight of its apples. We got to pruning, and now have a nice little pile of applewood sticks. I began whittling a few of these, and had the idea of making a letter opener from this dense, fine-grained stuff. Noticing the curve of the particular stick I was working, I had the idea of making this a katana.
After getting the sword shape, it took some careful belt-sanding to get a fine edge (my camera doesn’t do very good close-ups). This is more than capable of opening a letter.
Wanting to protect the blade, I made a sheath for it from oak and black walnut. I got some scrap oak about the same thickness as the blade, traced its profile, and cut it out with a band saw. This inner face was lined with green felt. Allowing a 1/8-inch around this profile, I shaped the outer face of the sheath. I glued two 1/8-inch pieces of black walnut to make the walls, and smoothed the overall shape.
After carving out the letters “alpha,” “phi,” and “omega,” I applied a coat of clear varnish. Here’s the end result:
I have yet to give it to my “big,” as I have not seen her since last Spring.