Samurai Pt 1 archive

Friday 24 April 2009

Fred and Julie Byrne make this wonderful scrollsaw toy project


We have tried to capture the Samurai with a look of proud arrogance, befitting a mighty Warrior. We have used a combination of 19mm Walnut, Sycamore and Tulip wood, but any assortment of wood off cuts you have would work just as well. The only stains used were Charcoal to darken the hair and some parts of the sword.


First make sure your chosen wood is completely flat, sand if necessary for however careful you are cutting out the pieces, you will not achieve a good 'fit' once the pieces are placed together, if it is warped in any way.

It's the same with the scrollsaw blade, taking time to make sure it's perfectly straight (a small try square is great for this) and taut at the outset will save time and limit the chance of any unsightly gaps between the pieces.

Getting started

Enlarge the pattern to the desired size and then use either carbon paper to transfer the pattern onto the wood or make multiple copies, cut into sections so each piece of the pattern can be position (using the directional arrows) and glued onto the wood following the grain (pics 2,3)

Cutting out

Fit the Scrollsaw with a No.5/7 blade and start to cut out the pieces (pic 4) using masking tape will help hold the pieces together (pic 5) as you progress and while you double check the cut line of the next adjoining piece, retracing a new cut line if necessary.

Change to a smaller No.2 blade to cut out the more delicate face pieces (pic 6) we have left the eye as one piece seeing it is so small, and have just used a permanent black marker pen to colour in the iris.

Once all the pieces are cut out you could leave the Samurai flat, without shaping if wished (pic 7) and simply finish off by hand sand all the pieces smooth.

In the next part: Sanding, shaping and finishing your warrior to give him an effective 3D appearance!

Click here for: Part 2

David Preece

Tagged In:

Fred Byrne , Julie Byrne , Scrollsaw , Samurai , Toy

"We have tried to capture the Samurai with a look of proud arrogance"

Diagrams Click an image to enlarge