LK Chen Han Sha 漢鎩 Assembly
The Han Sha was one of the five main weapons of the Han Dynasty Military (202 BC-220 AD). The Sha is powerful pole arm defined by its formidable thrusting power and lethal cutting ability. The extended cross guard could easily bind to the opponent’s weapons and protect the hand of the wielder. Because of its massive blade and custom shaft, the Sha was costly in both time and money to make, therefore only skilled warriors and elite guards were trusted to possess and use the weapon.
Han Sha 漢鎩 Parts
The Han Sha will arrive in 7 parts.
1. Custom painted hardwood shaft
2. Forged and heat treated Sha Blade with full tang
3. Scabbard
4. Brass cross guard
5. Leather cord
6. Wooden pins (x2)
7. Single strip of wood shim
Additional Materials for Assembly (not included)
1. Slow curing silicone adhesive
2. Gloves for handling sharp blades
3. Wooden or PVC Mallet
4. Scrap block of wood
5. Plastic straw (wide enough to fit leather cord)
6. Acute angle diamond file
Preparation
Tape Markers
Do not remove the marking tape on the blade, shaft, cross guard or scabbard. Tape markers are placed on specific sides of the parts that align for the perfect fit. Removal of tape markers or disregard can result in misalignment of the final assembly.
Dry Fit
A dry fit will be helpful to verify that the holes in the wooden shaft and tang correspond. Another fit to check is the brass cross guard and blade.
Wooden Pin Preparation
The wooden pins are meant to fit tightly through the wooden shaft and tang of the blade. They may be too wide upon arrival, which can be easily remedied by carving the tip with a blade until it fits through the tang, then rotating and pressing the pin completely through the tang to reduce it to the perfect size. An alternate option to the wooden pin provided, is a copper pin which can be custom fitted to match the dimensions of the hole diameter for the tang and shaft.
Han Sha 漢鎩 Assembly
After the preparatory steps have been completed assembly of the Han Sha may begin.
1) Assemble the guard from the tang side, sliding it up to the blade.
2) Apply generous amounts of glue to both sides of the tang as well as inside of the channel on the shaft. Insert the tang, wiping any excess away, until the tip of the shaft rests in the guard. The blade and cross guard are held onto the shaft by tension which will require much more pressure for the final inch. The recommended method is to place a flat piece of scrap wood on the ground and press the tip of the Han Sha blade into the wood, while pressing downward on the shaft until the holes in the shaft and tang align.
(Do not use the scabbard while pressing the tang into the shaft as it will damage the scabbard)
3) Insert the wooden pins through the shaft and tang using a mallet, and cut off any excess material with a blade or chisel. A saw may be used, but can potentially scratch or chip the surrounding area on the shaft.
4) Cut the wooden shim to fit the length of the channel and apply glue before inserting into channel on either side of the tang.
5) Wipe any excess adhesive and use clamps, steel ties, string, or rubber bands to compress the shaft and tang, then let rest the appropriate amount of time for the glue to dry (refer to the glue label).
6) Wrap the handle starting at the guard with the tip running downward 3”, then beginning at the guard, coil tightly downward. Continue coiling to cover the tang, and tang channel, occasionally twisting with your hand to increase tension and hold. At the last few inches, rest a straw underneath the coil and when the desired length for the wrap is reached, insert the loose end of the strap completely into the straw, and pull the straw upward and out through the coil, cutting any excess that emerges from the coil.
Your LK Chen Han Sha 漢鎩 is now completely assembled.
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