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Get a softwood which is about half inch thick - X 2 (one for each side)

place the blade on the wood and draw a rough line a couple of millimenters wider than the blade. use a vise to secure the wood to your bench. use a wood router to cut into the shape you drew and hollow out a couple of millimeters out of the wood. place your blade into the groove to see if it fits, then slide the blade thru the gap to see if it goes thru without catching. the more curved the blade is the more chance there is having to re-cut the wood to shave away the edges. once the blade goes into there niceley then do the same for the other peice of wood.

once you are happy with the insertion of the blade, cut the wood with a jigsaw. you should now end up with two square edged peices in the shape of your blade. use a small plaine to cut away the square edges, then use some sandpaper to smooth out the wood, trying to keep both sides symetrically and niceley curved.

get some wood glue and glue the edges of the wood where they will touch the other peice, and hold in place, use some sewing string or dental floss to keep the peices of wood together to reduce sliding. leave the wood glue to dry overnight.

get some thin leather, there is a good shop near the bullring in birmingham which sells leather ideal for miyaans. cut it roughly to the length and circumfrence of the miyaan wood, and roughly mark out the curve of the blade, turn the leather inside out and stitch it. once it is stitched it can go onto the wood, you can choose to glue it onto the wood but id advise against it, if the miyaan leather gets damaged you can always replace it easily without havin to mess about with strippin the glue off the wood.

hope that helped.

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waheguru ji ka khalsa waheguru ji ki fateh

dhanvad every1, will try these methods out. gurbar akaal ji, thanks for ur detailed description, i will definitely be using this method for one miyaan-less kipan i have, not so sure if it will suit the other one i have comin in soon. does anyone know how to make a miyaan in puratan style? similar to the one in this link but with a leather coatin.

http://oriental-arms.com/item.php?id=2199

waheguru ji ka khalsa waheguru ji ki fateh

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It will follow the same description above, but the routing will have to be different because the blade has a reinforced spine, so you'll have to chisel some extra wood for the spine to follow down.

The chape on the end of the miyaan takes more skilled work, basically you cut a thin peice of sheet metal, and fold it similar to a cone, weld it and fit it to the miyaan end. The intricate designed on the end of the chape comes down to skill and the tools you have.

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