Intarsia Samurai Warrior

The main objective is to try and capture, that look of proud arrogance, befitting a mighty Warrior!

We"ll be using a combination of 19mm Walnut, Sycamore and Tulipwood


Tips: Sanding and Shaping
Try to visualise the shape of the figure as you sand, and begin by sanding down the pieces that you know will be lower i.e. the neck, upper part of the left arm and left leg, this will instantly give the illusion that one piece is standing out more than another


1.  Getting started

Use either carbon paper to transfer the pattern onto the wood or...



2.  make multiple copies and cut into sections so each piece of the pattern can be used



3.  Attach each section of the pattern onto the wood (which has to be said, shows up so much better on the Walnut) aligning the directional arrows with the grain of the wood


4.  Cutting out.

After checking that the wood pieces are completely flat and the Blade set at
90 degrees to the table.

I can finally start to cut out the pieces


5.  As I cut out each piece, I like to use masking tape to keep the pieces together



6.  I always check the cut line against the adjoining piece before cutting, then if necessary I use the cut piece to trace a new cut line!



7.  I change to a No.2 Blade to cut out the small pieces within the face



8.  With Samurai completely cut out
You could leave it completely flat and simply hand sand all the pieces smooth, or better still take it to the next stage and sand some of the  pieces down lower to give your Samurai a 3D look.  

         See Sanding & Shaping Tips


9.  Sanding

Lower the upper arm on the left hand side, this instantly makes the fore arm appear forward



10.  Lower the top part of the left leg, mark the height against the sleeve, giving you a guide to later sand to



11.  Mark the height of the right sleeve onto the adjoining piece



12.  When you're happy all the different height levels
Mark the height of the lower pieces onto the adjoining higher pieces, so when you come to use the Drum Sander to round over the edges and sand the pieces smooth (going with the grain) you do not sand below your pencil lines.


13.  Leave the axe detail slightly raised



14.  Finishing the pieces

We've applied a coat of Charcoal wood stain to some parts of the Walnut, to highlight the hair, eyebrow and some pieces of the sword.

Then we apply an Acrylic Sanding Sealer to all the pieces.



15.  Making the Backing

After assembling the Samurai onto a piece of 6mm plywood, carefully draw around the inner and outer edges.

Then drill a blade entr hole...



16.  Insert the blade to make the inner cut.



17.  Assembly

Arrange the pieces of the Samurai in order to make gluing up easier, apply glue to each piece in turn and press firmly in position, wipe away and excess glue before it dries.


18.  Nearly there!

When completely dry, hold the Samurai between your thumb and forefinger until it hangs straight, mark the position with a pencil and then fit the D-ring.

Finished... :-)





     FREE - Samurai Warrior - Pattern



Click to download FREE Pattern
Samurai Warrior.pdf
Adobe Acrobat document [4.3 MB]
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