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Old 4th February 2012, 06:51 PM   #3
Atlantia
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Join Date: Jun 2008
Location: The Sharp end
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Hi Lotfy,

At what point of the construction of the wood formers are you having difficulty?
If it were me I'd.......
Start by selecting the wood. I don't know what type is usual, but any fairly soft but seasoned wood should do.
You want two bits obviously, one slightly fatter for the top side.
Make a cardboard template, a few mm larger than it should be, trace it onto both parts and cut them out.
At this point I'd probobly use a line of glue right down the middle to fix them together and let it dry.
Then I'd start shaping the wood. They are usually flatter on the back and more domed on the front. You don't have to get it perfect as it'll all be covered.
I'd suggest using files rather than power tools. Take it slow and get it right.
When it's 'nearly there' smooth with sandpaper.
Split the two halves and trace the blade outline. I'd use something like a dremel to cut the slot for the blade but a purist might want to use a chisel.
keep trying for fit and remember that the wood formers stop short of the top of the top silver sleeve.
When you've got the fit right then glue the two sides together and wait for ti to dry, then you can start thinking about how you want to cover the gap.
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