HISTORICAL EVOLUTION OF SAMURAI ARMS AND ARMORS

JAPAN, 700 AD 1880 AD

An Interactive Qualifying Project Report
submitted to the Faculty
of the
WORCESTER POLYTECHNIC INSTITUTE
in partial fulfillment of the requirements for the
Degree of Bachelor of Science
By
Korapat Lamsam
Cory Lauer
Paul Shepanski
Michal (Michelle) Talmor
Date: May 3, 2012

Submitted to:
Professor Diana A. Lados
Mr. Tom H. Thomsen

Abstract
The samurai warrior class of Japan has always fascinated the western world due to the
intriguing contrast between their strict military training and frightening efficiency, and their
deeply spiritual customs and surprisingly refined artistic talents. The purpose of this project was
to explore the evolution of this contrasting nature from the inception of the samurai class around
the 8th century to its abolishment in the 19th century, and to see how this cultural evolution and
the evolution of available materials and processing methods affected the construction and
characteristics of the samurais weapons. Out of these weapons, the katana, the signature long
blade of the samurai class was the primary focus. As part of this project, a sample katana was
constructed using near-traditional methods and its material properties were explored using
modern mounting and inspection techniques. In addition, the previous years project website was
updated to include the efforts made during this project.

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Acknowledgements
Wed like to thank Professor Diana A. Lados and Mr. Tom H. Thomsen for guiding us
through the amazing venture into the world of historical evolution of materials and cultures that
this IQP has been for us. We would also like to extend our appreciation to Joshua Swalec, who
dedicated both his time and his forge to this project. His instructional advice and great expertise
were instrumental to our effort to create a replica of a samurai katana using traditional forging.
Lastly, we would like to thank Professor Boquan Li who patiently instructed us on how to
mount, polish and etch samples and how to properly operate the Vickers microhardness and the
Rockwell hardness machines. Without all of these individuals, this project would not have been
as comprehensive and successful as it was. Thank you.

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Table of Contents
Abstract ........................................................................................................................................... ii
Acknowledgements ......................................................................................................................... iii
Authorship ..................................................................................................................................... vii
List of Figures ................................................................................................................................ ix
1. Introduction ............................................................................................................................... 1
2. Review of Japanese History 710 AD 1870 AD ..................................................................... 3
2.1 The Nara Period: Humble Beginnings .................................................................................. 3
2.2 The Heian Period: Rise of the Samurai................................................................................. 4
2.2 The Kamakura Period: The Shogunate, Rule of the Samurai ............................................... 6
2.3 The Sengoku Period War Among the Daimyos ................................................................. 6
2.4 The Azuchi-Momoyama Period - Unification & Order ........................................................ 8
2.5 The Tokugawa Period Peace & Prosperity ........................................................................ 9
3. The Samurai the Ultimate Warrior Class ......................................................................... 11
3.1 Social Structure ................................................................................................................... 11
3.1.1 Clan Formation ............................................................................................................ 11
3.1.2 Clan Loyalty................................................................................................................. 12
3.2 Religious Beliefs & Culture ................................................................................................ 13
3.2.1 Shinto ........................................................................................................................... 14
3.2.2 Confucianism, Buddhism & Zen ................................................................................. 15
3.2.3 Bushido ........................................................................................................................ 17
3.3 Tactics ................................................................................................................................. 18
3.3.1 Development of Armies ............................................................................................... 18
3.3.2 Primary Weapons ......................................................................................................... 19
4. The Katana a Samurais Spirit ........................................................................................... 21
4.1 Description & Anatomy ...................................................................................................... 21
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4.2 History................................................................................................................................. 23
4.2.1 Introduction of the Curved Blade ................................................................................ 23
4.2.2 Emergence of the Stronger, Shorter Katana ................................................................ 24
4.3 Cultural & Religious Meaning ............................................................................................ 25
4.3.1 The Meaning of the Katana to the Samurai ................................................................. 25
4.3.2 The Meaning of the Katana for the Sword Smiths ...................................................... 26
4.4 Materials & Manufacturing Process ................................................................................... 27
4.4.1 Smelting the Steel ........................................................................................................ 27
4.4.2 Forging the Katana ....................................................................................................... 30
4.4.3 Final Quench ................................................................................................................ 33
4.4.4 Constructing the Handle & Sheath .............................................................................. 36
4.4.5 Wrapping the Handle ................................................................................................... 37
5. Other Weapons of the Samurai ............................................................................................. 42
5.1 The Wakizashi .................................................................................................................... 42
5.1.1 History of the Wakizashi ............................................................................................. 42
5.1.2 Characteristics of the Wakizashi .................................................................................. 43
5.1.3 Materials Used in the Wakizashi ................................................................................. 43
5.2 The Tanto ............................................................................................................................ 44
5.2.1 History of the Tanto ..................................................................................................... 44
5.2.2 Characteristics & Materials of the Tanto ..................................................................... 45
5.3 The Bow .............................................................................................................................. 45
5.3.1 History of the Bow ....................................................................................................... 45
5.3.2 Characteristics of the Bow ........................................................................................... 46
5.3.3 Training with a Bow .................................................................................................... 47
5.4 The Spear ............................................................................................................................ 48
5.4.1 History of the Spear ..................................................................................................... 48
5.4.2 Characteristics of the Spear ......................................................................................... 48
6. Armors of the Samurai ........................................................................................................... 50
6.1 The Helmet.......................................................................................................................... 50
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6.2 The Chest Piece................................................................................................................... 51

6.3 Additional Armor ................................................................................................................ 55
7. Constructions of a Sample Katana ........................................................................................ 57
7.1 Materials Used .................................................................................................................... 58
7.2 Process ................................................................................................................................ 62
7.3 Results ................................................................................................................................. 69
8. Conclusion ............................................................................................................................... 78
9. Bibliography ............................................................................................................................. 79
10. Figure References ................................................................................................................... 82
11. Table References ..................................................................................................................... 85
11. Appendices .............................................................................................................................. 86
Appendix A: Glossary............................................................................................................... 86
Appendix B: Collected Material Hardness Data ....................................................................... 93
Appendix C: Updating the Online Database Site ..................................................................... 95
Appendix D: Katana Making Process Documentation ............................................................. 98

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Authorship
Korapat Lamsam

The Nara Period: Humble Beginnings

The Heian Period: Rise of the Samurai

The Katana, History

Other Weapons of the Samurai, The Wakizashi

Other Weapons of the Samurai, The Tanto

Glossary

Cory Lauer

The Tokugawa Period Peace & Prosperity

The Katana, Materials & Manufacturing Process

Construction of a Sample Katana, Plan

Construction of a Sample Katana, Materials

Construction of a Sample Katana, Process (co-written)

Paul Shepanski

The Azuchi-Momoyama Period Unification & Order

Other Weapons of the Samurai, The Bow

Other Weapons of the Samurai, The Spear

Armors of the Samurai

Construction of a Sample Katana, Results

Conclusion
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Michal (Michelle) Talmor

Abstract

Acknowledgements

Introduction

The Kamakura Period: The Shogunate & the Samurai Ruling Class

The Sengoku Period: War Among the Daimyos

The Samurai the Ultimate Warrior Class

The Katana , Description & Anatomy

The Katana, Cultural & Religious Meaning

The Katana, Materials & Manufacturing Process, Wrapping the Handle

Updating the Online Database Site

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List of Figures
Figure 1: Katana Anatomy Different Parts of the Blade............................................................ 22
Figure 2: Katana Anatomy Different Parts of the Handle. ........................................................ 23
Figure 3: Ceremonial Nature of Blade Forging. ........................................................................... 27
Figure 4: Tatara Furnace Schematics. ........................................................................................... 28
Figure 5: Tatara Furnace Burning Iron into Tamahagane Steel. .................................................. 30
Figure 6: High Carbon Tamahagane Steel Squares. ..................................................................... 31
Figure 7: Hard Steel Shell Initial Block Formation. ..................................................................... 31
Figure 8: Formed Soft Steel Core to be Inserted into the Hard Steel Jacket. ............................... 32
Figure 9: Blank, 90% of Desired Length, vs. Fully Shaped Blade. .............................................. 33
Figure 10: Shaving Off Irregularities in the Blade. ...................................................................... 33
Figure 11: Covering the Blade with Clay for the Final Quench. .................................................. 34
Figure 12: Quenching of the Blade in a Trough of Water. ........................................................... 35
Figure 13: Adjustments to the Final Blade via Gentle Hammering.............................................. 35
Figure 14: Samegawa, Stringray Skin with Nodules. ................................................................... 38
Figure 15: Tsukamaki Wrapping Triangle Pattern. ...................................................................... 40
Figure 16: Menuki Insertion into the Handle. ............................................................................... 40
Figure 17: Full, Mounted Katana with Wrapped Handle & Sheath. ............................................ 41
Figure 18: Comparison Between Long Katana & Shorter Wakizashi. ......................................... 42
Figure 19: Example of a Tanto from the Kamakura Period.......................................................... 44
Figure 20: Drawing a Japanese Bow From Above the Head. ....................................................... 47
Figure 21: Archery Training via Competition Challanges. .......................................................... 47
Figure 22: Comparison of Spear Lengths based on the Army (Latest to Earliest). ..................... 49
Figure 23: Example of a Decorated Kabuto with False Hair. ....................................................... 51
Figure 24: Sample of Scaled, Lamellar Armor. ............................................................................ 52
Figure 25: Traditional Samurai Do-Maru Armor. ........................................................................ 53
Figure 26: Example of Europe-Influenced Japanese Plate Armor................................................ 54
Figure 27: Example of Sode from the Edo Period. ....................................................................... 55
Figure 28: Example of a Full Piece of Edo Period Decorative Armor. ........................................ 56
Figure 29: Silk Cord for Katana Handle Wrap. ............................................................................ 60
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Figure 30: Stingray Skin for Katana Handle Wrap. ...................................................................... 60

Figure 31: Finishing for the Sample Katana. ................................................................................ 61
Figure 32: 1095 Steel Forging. ..................................................................................................... 62
Figure 33: Joined 1018 Steel and 1095 Steel. ............................................................................... 63
Figure 34: Brittle Failure of the Hard Steel/Soft Steel Blade. ...................................................... 64
Figure 35: 5160 Blade Second Attempt. ....................................................................................... 64
Figure 36: Grinding the Sword. .................................................................................................... 65
Figure 37: Final Blade with Silvery Finish. .................................................................................. 65
Figure 38: Applying Refraction Clay to the Blade Before Quenching. ........................................ 66
Figure 39: Quenching the Blade. .................................................................................................. 66
Figure 40: Carved Tsuka Handle. ................................................................................................. 67
Figure 41: Cut Same Piece & Handle Wrapping Tools. ............................................................... 68
Figure 42: Wrapped Handle Assembly, Left to Dry Overnight.................................................... 68
Figure 43: Silk Ito Wrapping. ....................................................................................................... 69
Figure 44: Final Replica of a Katana. ........................................................................................... 70
Figure 45: Etched & Mounted Blade Sample. .............................................................................. 71
Figure 46: Vickers Hardness Results across Both Steel Sections................................................. 73
Figure 47: Vickers Hardness Results across the Boundary between Steels. ................................ 73
Figure 48: Grain Images Above & Below the Soft/Hard Steel Boundary. ................................... 74
Figure 49: Fe-C Phase Diagram. ................................................................................................... 75
Figure 50: New Website Main Template with Sidebar Navigation. ............................................. 95
Figure 51: More Spacious Template with Top Navigation. ......................................................... 96
Figure 52: Clickable Map and Navigable Time Periods Example. .............................................. 96
Note: Figure references can be found after the Bibliography section.

1. Introduction
This project is a part of the Historical Evolutions of Materials in Arms and Armors
Interactive Qualifying Project series. The primary purpose of this project is to examine the
evolution of the weapons and armors of the samurai warrior class of Japan, in terms of design,
materials and manufacturing process, within the context of the samurais tumultuous history and
intricate culture. Another main goal of this project is to record the construction of a replica of
one of the weapons used by the samurai and analyze the material properties of the result. The last
purpose of this project is to update the online database website that was developed for the
previous iteration of this project series with the information gathered during this project.
The samurai, one of the most famous military forces in the world, emerged during the 7th
century in pre-medieval Japan and remained active until their abolishment in the late 19th
century. Originally used as mercenary forces, the samurai quickly became the primary military
force in service of the Japanese Empire and, soon after, the effective ruling class of all Japan.
Although the samurai transitioned relatively rapidly from simple military lives to high court
functions and inter-clan intrigues, their military-inspired core values and moral codes were
religiously maintained. In fact, their refined sense of honor and devoted spirituality were so
prominent that they inspired great tales of valor that resound with readers to this very day. This
strange balance between deadly efficient military might and gentlemanlike noble nature is
exemplified by the graceful weapons and armors that the samurai carried and wore.
In order to illustrate the cultural evolution of the samurai and the evolution of their arms
and armor in the proper historical context, this report begins with a brief historical review of the

six main time periods that the samurai were active in between the 7th century and the 19th
century, followed after by a review of the samurais evolving culture throughout these periods.
This report then details the evolution of the samurais weapons and armors, based on the
historical and cultural information that was provided in the beginning sections. The main
questions that this report attempts to answer for these arms and armors are:

What designs were originally used?

What materials were originally used?

What manufacturing processes were originally used?

How did these designs, materials and manufacturing evolve over time?

What was the historical and cultural context of each stage of this evolution?

Finally, a record of how our team constructed a replica of a katana, the signature samurai
long blade, is given along with an analysis of the material properties resulting from the forging
process of such a weapon.
For the convenience of the reader, a glossary of the main Japanese terms used in the course
of this report is provided in the appendix section.

2. Review of Japanese History 710 AD 1870 AD

In order to understand the cultural evolution of the samurai, as well as the evolution of
the shapes and materials of their weapons and armors, one must understand the historical events
that led to the samurais rise, prominence, and eventual decline. These events can be divided into
six distinct periods:

The Nara Period, 700 AD 794 AD

The Heian Period, 794 AD - 1185 AD

The Kamakura Period, 1185 AD - 1467

The Sengoku Period, 1467 AD - 1573 AD

The Azuchi-Momoyama Period, 1573 AD - 1603 AD

The Tokugawa Period, 1603 AD - 1876 AD

This chapter therefore provides a description of each period and the main events that

occurred within each period. It should be noted that this is not a comprehensive review of each
time period, but only a summary of the main events of each period that pertain to the samurai.

2.1 The Nara Period: Humble Beginnings

The roots of the samurai lie in the Nara Period, a period between 710 A.D. and 794 A.D.
marked by continues heavy Chinese influence on Japanese culture, technology, and military
doctrine (Van Goethem, 2008). Japans government at the time mirrored that of China,
consisting of political, rather than military, leaders. Unlike previous eras, the Emperor and
Imperial court were content to watch conflicts unfold from afar, unwilling to ride into battle as
their predecessors often did (Brynat & McBride, 1989). The military was modeled after its

Chinese counterpart, requiring every capable man in Japan to enlist under the direct command of
the emperor (Turnbull, Samurai Warfare, 1996).
While these ill-trained draftees, known as heishi, made up the vast majority of the
Imperial Army, it also contained a small professional, mounted fighting force that grew as the
period progressed (Turnbull, Samurai Warfare, 1996). Slowly, the peasant and military classes
separated, a process greatly accelerated by Fujiwara clan-leader and Imperial court member
Fujiwara Nakamaro, who relied on professional military men over conscripted heishi soldiers
(Bryant, Early Samurai AD 200-1500, 1991). The idea of a professional army grew more and
more popular, culminating in the abolition of the draft in 792 (Turnbull, Samurai Warfare, 1996).
In place of heishi, warriors from regional, mercenary clans filled the ranks of the imperial
military. Thus, by the close of the Nara Period, Japan had a more professional army, comprised
of the very first of the samurai. These samurai began forming into clans during the Heian period
(Turnbull, Samurai Warfare, 1996).

2.2 The Heian Period: Rise of the Samurai

The Heian Period, lasting from 794 AD to 1192 AD (Turnbull, Samurai Warfare, 1996)
marked the samurais true rise to power. Considered by many to be the peak of Japanese cultural
development, the period represented a shift from the adoption of foreign practices to the
development of internal ones (Kitagawa, 1990). As Japans culture bloomed, the power of the
samurai clans did as well. During this period, houses and clans of samurai began to form
(Bryant, Early Samurai AD 200-1500, 1991). The feudal lords of these clans were able to obtain
land and control it with the samurai armies under their command. Able to provide lower taxes
and better protection for the common people in their land than the increasingly disconnected

central government, the samurai slowly won the loyalty of the people (Sansom G. B., 1978). As
the central Emperors power slowly declined, the regional samurai clans became the de-facto
rulers of the provinces and the dominant forces in both the economic and political arenas.
However, as the clans power grew, so did their conflicts. With the central government
too weak to intervene, samurai clans were free to act in their own interest against other clans and
the government. The late Heian Period saw a large increase in rebellions, such as the Masakodo
Rebellion in 935, the Early Nine Years War in 1055, and the Later Three Years War several
years later (Brynat & McBride, 1989). In addition, war between the clans was rampant as well.
The big samurai families of the time were the politically influential clan Fujiwara, and the
samurai military clans Taira and Minamoto (Turnbull, Samurai Commanders 940-1576, 2005).
Their battles shaped the era, culminating in the Gempei War of 1180, in which the Minamoto
clan rebelled against the current Taira clan rule and seized the capital of Kyoto, forcing the
Emperor to proclaim the Minamoto leader Shogun; grand military general and effective ruler of
Japan. The Emperor was then effectively banned from participating in the government and was
relegated to a purely ceremonial role (Turnbull, The Samurai Sourcebook, 1998). The results of
Gempei War fully cemented the Shogunate as the new form of government and officially
declaring the samurai as the ruling class of Japan. The birth of the Shogunate was the beginning
of the Kamakura period (Turnbull, The Samurai: A Military History, 1996).

2.2 The Kamakura Period: The Shogunate, Rule of the Samurai

The establishment of the Minamoto Shogunate ushered in the Kamakura Period, a golden
age for the samurai spanning the years between 1192 AD and 1467 AD (Turnbull, Samurai
Warfare, 1996). During this time, the Minamoto clan built a strong feudal government based on
military might and the rule of the Shogunate the government of the Shogun over all samurai
houses and over all Japan by extension. This period marked the height of the military strength of
the samurai class under the stable rule of the Shogunate. The Minamoto Shogunate ruled Japan
for almost 150 years and was able to successfully repel two Mongol invasions in 1274 and 1281
(Turnbull, Samurai Warfare, 1996).
In 1331, a failed attempt by Emperor Go-Daigo to restore imperial rule toppled the
Minamoto Shogunate, allowing his Ashigaka clan allies to assume control of the Shogunate in
1338 (Turnbull, The Samurai: A Military History, 1996). These allies later turned on him,
sparking a war that ended with the Ashigaka solidifying their Shogunate rule in 1392 and forcing
the line of emperors out of the government again. An uneasy peace reigned throughout Japan
from this point until 1467, when the outbreak of the Onin War ended the Shogunates golden age
(Turnbull, The Samurai: A Military History, 1996). The Onin war marks the beginning of the
Sengoku period of Japanese history.

2.3 The Sengoku Period War Among the Daimyos

The events of the Sengoku Period, which lasted from 1467 AD until 1573 AD, dealt a
great blow to the Shogunate institution. Beginning with the ten year Onin War of 1467, the
Sengoku Jidai (Warring States Period) was a period of all-engulfing war and chaos for Japan.
A dispute between two influential family heads over the future heir of the Shogun ignited long6

standing tensions between Samurai noble families (Brynat & McBride, 1989). As violence
erupted in the capital of Kyoto and across Japan, the Shogun stood by and did nothing to quell
the fighting. In the power vacuum generated by the conflicts and the apathetic Shogunate, many
resourceful individuals seized the opportunity to gain or strengthen their own positions
(Turnbull, Samurai Warfare, 1996). These individuals rallied anyone who wanted to fight to their
side and made themselves lords over local domains. Thus, the daimyos ,[big] names (Turnbull,
Samurai Warfare, 1996), were born out of both the few who managed to keep their power during
the conflagration and those who were wise enough to seize power during the chaos. Without the
Shogunates involvement these local domains had full autonomy and could operate based on
local laws without paying taxes or owing anything to the decaying central government.
Accountable only to themselves, the daimyos were free to pursue their own agendas, resulting in
intense infighting that only the strong were able to survive (Brynat & McBride, 1989).
As a result the Sengoku Period saw a large rise in ashigaru forces; foot soldiers recruited
from the commoners with little equipment or training (Turnbull, Samurai Warfare, 1996). With
food and coin difficult to come by due to the constant fighting, many of the less affluent daimyos
chose to rely on the ashigaru in their employ over the much more expensive samurai. The
importance of the easily re-trained ashigaru only increased with the Portuguese introduction of
guns to Japan in 1542 (Brynat & McBride, 1989). Learning to use a gun was relatively easy and
with enough guns and expendable men an army could fill the air with shots that were sure to be
devastating, regardless of where they hit. This made the ashigaru forces nearly as important to
the militaries of the time as the elite samurai archers and spearmen (Turnbull, The Samurai
Sourcebook, 1998). The lessened reliance on samurai forces in favor of ashigaru, coupled with
the impotence of the Shogunate severely weakened the samurais standing. While samurai still

held their status as a prestigious, honorable, elite force, much of their old prestige and power
were lost (Louis & Ito, 2008). The samurai would never truly recover from these cultural losses.
After the chaotic times of the Sengoku period, Japan was in need of a strong leader that
could reunite the clans and restore peace. This leader was Oda Nobunaga, whose efforts mark the
beginning of the Azuchi-Momoyama period.

2.4 The Azuchi-Momoyama Period - Unification & Order

The Azuchi-Momoyama period, lasting from 1568 AD to 1603 AD (Louis & Ito, 2008),
can be described as the legacy of a single man; a legendary samurai named Oda Nobunaga.
Through strength of arms and shrewd political negotiation, he fought to reunify the war-torn
provinces of Japan and restore the Shogunate to power (Turnbull, Samurai Warfare, 1996). His
innovative tactics during this campaign, such as his use of Portuguese arquebus guns to defeat
samurai cavalry archers (Louis & Ito, 2008), prompted a shift further away from highly
specialized samurai troops. While Nobunaga was killed in an ambush in 1582 (Brynat &
McBride, 1989), his dream of a unified Japan was carried forward by his generals, resulting in
the complete reunification of Japan in 1590 by his general Hideyoshi (Turnbull, The Samurai
Sourcebook, 1998).
With the reunification of Japan complete, Hideyoshi set about restructuring Japanese
society. He sought to heighten the division between the peasantry and the nobility by only
allowing the samurai nobility to carry swords (Louis & Ito, 2008). This separation of duties not
helped Japans weakened economy by allowing the peasants to focus on farming and mining
rather than warfare, but made rebellion by the lower classes more difficult as well. Furthermore,
it served to make the katana the symbol of the samurai, as they were the only ones allowed to
8

carry these weapons. At the end of Japans unification period, the samurai became more of a
standing national army, alongside ashigaru forces, that was only used when needed, rather than
the ever-fighting clan specific warriors they once were (Jansen, 2000).
After the restructuring of the Japanese worker and warrior classes, Japn settled into a
long period of peace known as the Tokugawa period.

2.5 The Tokugawa Period Peace & Prosperity

The establishment of the Tokugawa Shogunate in 1603 AD (Louis & Ito, 2008) ushered
in the Tokugawa period and the final stages of decline for the samurai class. With peace reigning
throughout Japan for the first time in hundreds of years, the need for the samurais martial
prowess was greatly reduced (Turnbull, Samurai Warfare, 1996). At the same time, economic
growth and a shift to coinage as the primary means of commerce elevated the merchant class, the
Chonin, above their traditional station, putting them on par with the idle samurai (Honjo, 1932).
The samurais land based economy of earlier periods fell apart, forcing many samurai to turn to
Chonin loans in order to support themselves.
As the period progressed and coin became ever more dominant, the samurai began to
falter. With no need for their combat skills, many turned into Chonin themselves, becoming
merchants instead of warriors. Others sold their feudal lands to pay off debts to Chonin,
transferring even more power into the hands of the merchant class (Honjo, 1932). The Shogunate
made several attempts to alleviate the samurais plight, including the cancellation of all loans
made to samurai at some point, but could not keep the samurai in good financial standing
(Jansen, 2000). Eventually, the situation became dire enough that the samurai revolted,
overthrowing the Shogunate and restoring an Imperial system (Jansen, 2000). Following the
9

revolution however, the new Emperor forcefully disbanded the samurai in 1876 as part of the
Meiji Restoration that began in 1864 (Louis & Ito, 2008). Thus, ended the samurai era in Japan.

The following chapter introduces who the samurai were, how their unique philosophy
developed over the course of their history and how this philosophy affected every aspect of their
lives, including their perception of warfare and styles of combat.

10

3. The Samurai the Ultimate Warrior Class

The word samurai means one who serves (Turnbull, The Samurai: A Military History,
1996). The samurai, therefore, are servants of their lord, of the emperor and of all of Japan. This
ultimate sense of duty, which is embedded in the samurais name, can be traced back to their
religious beliefs and cultural customs. This chapter contains information about the evolution
these beliefs and customs as well as the samurais view of combat and their role as warriors in
Japanese society. This information is given here to give better context for the development of the
samurais arms and armors, which is described in the following chapters.

3.1 Social Structure

As was mentioned in the historical review section, samurai and their families were
generally a part of a clan. One must wonder, however, how these clans formed, why they formed
and whether the clans operated as business units or expanded families. This section seeks to
answer these questions and shed more light on the social world of the samurai.

3.1.1 Clan Formation

Initially, around the Nara and early Heian periods, samurai had no distinctive clans. Each
samurai had his own web of connections to other samurai and lords, but was altogether his own
independent unit. It was therefore common for the samurai of that period to share their loyalty
among different clients that they provided mercenary services for. These bonds were businesslike, without the emotional connections that came in later periods (Ikegami, 1999).
In the late Heian period, however, clans of samurai began to form. These clans were
known as houses (ie) in Japanese. Originally, these houses were just a formalization of one-

11

to-one business relationships (Turnbull, Samurai Warfare, 1996). A lord with an estate would
offer his hired samurai housing in exchange for exclusive services from them. This housing offer
also extended to the samurais families. Over time, a strong sense of loyalty developed between
the lord and his hired samurai. Eventually, the samurai were incorporated into the lords
household and their lineages became a part of his clan, effectively joining the lords family
(Ikegami, 1999). The business relationship between the samurai and the lord was then
transformed into clan and family loyalty.

3.1.2 Clan Loyalty

In Japanese society, the core social unit has always been the family, rather than the
individual. The formation of the samurai clans therefore created a strong, self-contained military
unit whose loyalty to each other was equivalent to ones loyalty to ones own blood relatives
(Turnbull, Samurai Warfare, 1996). These new samurai clans played a pivotal role during the
Sengoku period, when Japan fragmented into fiefdoms. The strength of the fiefdoms was directly
related to the strength and size of the samurai clans that controlled them (Ikegami, 1999). Interclan warfare was therefore an important matter of protecting and strengthening the honor and
influence of each clan, and of each samurai lineage as a result.
However, this sense of familial loyalty and filial loyalty toward the clan and the clans
lord was a two-edged sword. Whereas the successes of the clan translated into the successes of
its lord and vice versa, the same could be said for the failures of both. A lords political blunders
reflected just as badly on the clans honor as losing a battle and the ultimate losses of honor for a
clan were either to suffer total loss in combat or to lose its lord and all his heirs. Samurai whose
heirless lord had been killed became known as ronin, leaderless and without honor. Ronin

12

were generally expected to follow their lord into death, sometimes while avenging their lords
honor as the Tale of the Forty-Seven Ronin depicts (Ikegami, 1999).
In some cases ronin or samurai were able to switch clans and still maintain honor. This
was much more popular before the peaceful Tokugawa period, since Japans political state was
in constant flux. In addition, a samurai clan could adopt individuals into the clan, such as warrior
monks or distinguished ashigaru. During the Tokugawa period, however, clans were much more
static and it was considered extremely dishonorable to change ones allegiance to a different
clan, even for a Ronin. The samurai clans of the Tokugawa period were more obsessed with the
concepts honor and loyalty than their predecessors since their primary role during the Tokugawa
peace had switched from active military to political nobility (Ikegami, 1999). By the end of the
Tokugawa period, many samurai had lost their lives to the concept of clan honor, whether via
voluntary suicide or via sanctioned inter-clan warfare.

3.2 Religious Beliefs & Culture

The religion of the samurai is a complex entity born out of the polytheistic melting pot of
religions that Japan had cultivated throughout its history. Thus, Japans native spiritual religion,
Shintoism, was supplemented by healthy portions of Buddhism and Taoism, which were
imported from China and other nations over time. This resulted in a strange mix of all three that
varied between each individual person, family or clan, based on personal preferences and
traditions (Kitagawa J. M., 1990). Compounded on top of this was the samurais own warrior
code, Bushido, which added its own flavor to the warrior class views of the common religions
of the time (Nitobe, 1905). There is therefore no wonder that sayings such as born Shinto, die
Buddhist developed in Japan, as the Japanese picked and chose which domains of life and death

13

each religion governed (Kitagawa J. M., 1990). This concept is essential to understanding how
the samurais specific mix of religious beliefs that is described below affected their culture,
values and choices in everyday life.

3.2.1 Shinto
Shinto, the native religion of Japan, is based on the worship of spirits and nature. Over
the course of Japans history, Shinto underwent several transformations due to the ever-changing
religious and political climates, but several of its core principles endured until the 19th century
and beyond. These core principles include the belief in Kami protector spirits or gods, filial
loyalty to ones head of family or clan, loyalty to ones ancestors, the need to keep one pure from
contaminations of the body and soul, and the belief that everything and everyone is
interconnected through a shared, intrinsic divine nature (Kitagawa J. M., 1990). These relatively
simple precepts made Shinto extremely popular in Japan over its entire history.
Even as Buddhism replaced Shinto as the primary religion in Japan after the Nara period,
Shinto still remained a substantial part of everyday life. The Emperors of the Nara and Heian
period sought to institutionalize Shinto alongside Buddhism because of its popularity so that,
while adopting many Buddhist customs, the Japanese people continued to pay their respects to
local Kami spirits during the Shinto religious holidays and prayed at Kami shrines before making
big decisions (Kitagawa J. M., 1990).
For the samurai, Shinto took on additional meanings in order to fit their unique social
nature as a warrior social class. For instance, filial loyalty was expanded to include loyalty to the
lord and head of the clan. Similarly, although each samurai had their own personal commitment
to their own honor and their ancestors honor, this too was expanded to include the honor of their
14

lord and his ancestors. In all other aspects, however, the Shinto customs of the samurai were the
same as those of everyone else (Kitagawa J. M., 1990).

3.2.2 Confucianism, Buddhism & Zen

As mentioned before, Buddhism slowly permeated Japan from the Nara period and on
until it became extremely prominent in Japanese culture, especially in the royal courts. However,
the pervasiveness of Shinto among the Japanese people forced Buddhism to change into
localized versions that included several concepts from Shinto and were unique to Japan.
For instance, several of the theoretical views of the original Buddhism religion were too
obscure and difficult to grasp for the common Japanese people. Many therefore chose to follow a
different path of Buddhism, called Zen. Zen had originally developed in China, under the name
Chan, which means meditation. At its core, Zen focuses on the concept that the ideas of
Buddhism and the true nature of things cannot be fully understood unless they are experienced
(Kitagawa J. M., 1990). Therefore, practitioners of Zen experience the here and now and find
within these experiences the hidden, true spiritual meanings and a kind of spiritual perfection
that would otherwise elude them if they simply tried to memorize them.
Zen also included beliefs of ridding ones mind of contaminations via meditation, which
resonated with the Shinto beliefs of purity that the samurai held. This also included ridding
oneself of imperfections as well, which explains the great care for detail and accuracy that we
associate with the samurai to this day. Therefore, starting with the Nara period, the samurai
began to incorporate Zen meditation into their daily training and their art and writing often
referenced Zen concepts, beliefs and customs (Kitagawa J. M., 1990).

15

These concepts of Zen were also in line with Confucianism, which also crossed over to
Japan from China. Confucianism is a humanist ethical system, in which man is believed to be
capable of controlling himself and his fate through learning and striving for self-perfection.
Confucianism also includes concepts of filial loyalty to ones family and ones ancestors.
Therefore, this way of thought came naturally to the Japanese people. The samurai were great
proponents of both Zen and Confucianism (Kitagawa J. M., 1990). Zen gave new religious
meaning to everything they did, transforming their lives into deeply spiritual experiences, and
Confucianism transformed their training and way of life into a sacred journey toward perceived
self-perfection.
As Shinto grew and changed as a result of Buddhism taking hold in Japan, the concept of
a Buddhist afterlife was incorporated into the Shinto belief. Originally, death in Shinto was
merely a matter of an impurity that had to be dealt with and an opportunity to add another
ancestor Kami to the pantheon of the family or the region. However, the Buddhist afterlife,
which is simply a continuation of life before death in a different world, was very appealing to the
Japanese people and to the samurai specifically. Under this new belief, death for the samurai
represented a great opportunity for glory and honor that would continue with them into the
afterlife. In addition, death did not release them from their loyalty bonds to their clan and to their
lord (Kitagawa J. M., 1990). This allowed the samurai to gladly take their own lives in the event
of their lords death, as the highest expression of loyalty and as a culmination of their journey
toward being the perfect loyal servant.
Many of the above ideas and precepts found their way into the samurai code of honor that
came to be known as Bushido, which is described below.

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3.2.3 Bushido
Bushido literally translates to military-knight-ways, or the precepts of knighthood. It
is the code of moral behavior that every samurai must uphold in order to be considered a true
samurai. The term Bushido came to be known during the early Tokugawa period, in the 17th
century. Up until then it had remained an unwritten, unofficial set of rules and ideas that was
passed from one generation of samurai to the next. Although the official Bushido code came into
being relatively late in samurai history, it drew many of its precepts from the early Shinto, Zen
and Confucianism concepts that the samurai had incorporated into their lives over time (Nitobe,
1905). Thus, stories of the reckless bravery of the samurai and extreme devotion to their lord
existed since the early Heian and Nara periods, such as The Tale of Heike, which became
popular during the 12th and 13th centuries and describes the great daimyos honorable behaviors
during the Gempei wars of the 12th century - well before the Tokugawa period (Ikegami, 1999).
The basic precepts of the Bushido code are justice, loyalty, honor, courage, love and
courtesy. The perfect samurai, therefore, is a man who upholds justice and honor as the highest
values, who is not afraid to go into battle or die for his lord, who loves all things in the world and
is capable of great compassion and who is a perfect gentleman in matters of etiquette.
Underlying these was the idea that the heart, and not the dry, intellectual mind, should guide a
samurais actions. These ideas unite the concepts of loyalty and connection with all things from
Shinto and the concepts of experiencing the moment and gaining glory and honor in death from
Zen into the Confucianism view of the perfect gentleman a cultured, learned man, skilled in
the art of war (Nitobe, 1905). In many respects, Bushido is the Japanese equivalent to the
European code of Chivalry that was upheld by the knights of the medieval ages.

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3.3 Tactics
Now that the social and religious contexts of the samurai have been reviewed, attention
can be given to the evolution of the samurais unique combat techniques. This section contains
information about the samurais changing roles in combat throughout their history, as well as a
brief review of the primary weapons of the samurai.

3.3.1 Development of Armies

During the Nara and Heian periods, samurai warriors were largely independent fighters.
Although they served together in their lords military, each samurai focused primarily on solitary
tactics that would stand out from the crowd, attract the attention of the lord and bring about a
promotion. Since each samurai warrior strived for perfection in his personalized tactic, when
grouped together they were an unstoppable force versus the untrained and easily intimidated
drafted forces that served as the main body of militaries at the time. Versus each other, however,
the fight was more evenly matched and many tales romanticize the battlefield duels between
opposing samurai and the clashing of their individual fighting styles (Ikegami, 1999).
During the Sengoku period, however, clans began to train their samurai as units that were
meant to fight collaboratively. During this tumultuous period, samurai-commanded armies
became larger and more skilled through experience, including the drafted ashigaru forces. This
meant that individual samurai could be overrun by semi-skilled ashigaru forces if they failed to
work together. Each samurai still worked toward achieving individual fame, but through strategic
genius and command skills rather than through mere fighting prowess. This trend continued into
the Azuchi-Momoyama period until the Tokugawa peace broke out (Turnbull, Samurai Warfare,
1996).
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3.3.2 Primary Weapons

The samurai have always been known as deadly, elite military units. However, their
greatest worth was not in front-line fighting with swords, but with providing support from
horseback. Before the 14th century, the most deadly and useful weapon a samurai wielded was
the bow (Turnbull, The Samurai Sourcebook, 1998). From horseback, the samurai were able to
rain arrows onto enemy troops either from a distance or from close combat while maintaining the
mobility and protection afforded to them by their mounts. Samurai frequently trained in how to
shoot a bow with both hands while galloping and competed in archery competitions in order to
increase their accuracy to a deadly precision (Turnbull, Samurai Warfare, 1996).
However, this changed during the Sengoku period. While in previous time periods only
samurai were allowed to use bows, ashigaru were now given this privilege as well. This meant
that instead of firing off a few, highly accurate shots, an army could simply fill the air with
arrows, since the ashigaru greatly outnumbered the small, specialized samurai forces. This
allowed the samurai to learn how to excel with a new weapon the spear. Spears could be used
both as thrown weapons and as stabbing weapons, while giving a samurai the advantage of a
greater reach than that of a sword and a greater distance between him and his target (Turnbull,
Samurai Warfare, 1996).
Throughout the samurais active military career the katana sword was rarely used. In
battle, it was reserved for close combat either from horseback or from the ground. However, such
situations were relatively infrequent and undesirable for the samurai. That said, the samurai were
still masters of the sword and trained with it incessantly. The greatest test of their skills,
however, was against each other, either during battlefield duels or during interpersonal and interclan feuds. During the Tokugawa period, when the military skills of the great majority of the
19

samurai were no longer needed, such clan feuds and personal duels became the primary combat
focus for this military elite (Ikegami, 1999). The primary weapon of the samurai of this period
was therefore the katana, for those who kept it rather than selling it for extra funds, or the
wakizashi, the smaller sister sword to the katana (Turnbull, Samurai Warfare, 1996).

Now that the samurais social, religious, and tactical roles throughout history have been
examined, the specific evolution of their arms and armors can be reviewed. The next few
chapters provide such a review of the evolution of the major weapons and armors of the samurai,
their composition and their construction methods.

20

4. The Katana a Samurais Spirit

The katana is the long sword that has always been associated with the Japanese samurai
warriors. The katana is primarily a slashing sword, but its unique structure allows it to also be
used as a stabbing weapon and a parrying weapon for defense (Turnbull, Katana: The Samurai
Sword, 2010), due to its high resilience. It can be used either one-handed or two-handed,
depending on the type of stroke to be delivered and the amount of force the samurai wished to
impart to the blow. The katana was worn with the cutting edge facing up, thrust into a samurais
wide belt (Joly & Hogitaro, 1913).
The katana underwent several changes since the introduction of swords to Japan from
China (Morimoto, 2004). This chapter will describe the primary features of the katana, its
historical evolution and the manufacturing process that was developed for it over time.

4.1 Description & Anatomy

The katana is comprised of a blade between two and three feet long. In general, the tang
is about a fifth of the length of the blade, with a hole near its end. The lengths of both tang and
blade have changed with time, however, as will be reviewed in the history section below. The
wooden handle, or tsuka, of the katana covers the tang fully. The handle is drilled through,
such that a peg could be inserted into it, through the hole in the tang, in order to secure the
handle onto the blade. The wood of the handle is usually covered with leather or stingray skin
and then wrapped with rough silk cord, to provide a better grip (Joly & Hogitaro, 1913).
The blade itself is slightly curved, with a single sharp edge on the convex side of the
curve. The blade has a ridge running along it and ends at a sharp point. Along the blades edge, a

21

distortion pattern called the hamon can be seen. This pattern is used as a measure of the quality
of the blade and its composition (Turnbull, Katana: The Samurai Sword, 2010).
At the point where the katanas handle and its blade meet, a hand cross guard called a
tsuba is often present. The tsuba is both practical and decorative and can be made of more
precious metals than steel. The wrapped can also be fitted with ornamental fittings that match the
tsuba, for a more decorative look. Sometimes, spacers are used on one or both sides of the tsuba,
to provide a tighter fit for it and a collar is fitted onto the base of the blade to provide extra
strength to the point where the blade and cross guard meet (Turnbull, Katana: The Samurai
Sword, 2010).
A decorative, small crest piece, called a menuki is often embedded into the handle,
peeking out from between the wrappings. This crest piece usually belonged to the person or clan
for whom the sword was made (Joly & Hogitaro, 1913).
The images on the next page show a full guide to the names and locations of the different
parts of a katana and its handle.

Figure 1: Katana Anatomy Different Parts of the Blade.

22

Figure 2: Katana Anatomy Different Parts of the Handle.

4.2 History
The katana is the result of nearly a thousand years of sword refinement, the final stage in
a process of continuous evolution dating back to the creation of the first Japanese swords in the
5th century. This section describes the evolution of the katana from its humble beginnings to its
place of honor in Japanese society.

4.2.1 Introduction of the Curved Blade

The first swords were known as Chokuto, Straight Swords, and were little more than
steel long swords derived from Chinese and Korean designs. Long, straight, and single-edged,
they lacked the distinct curvature that defines the katana as it is known today (Morimoto, 2004).
The curve emerged during the Nara Period, as a result of sword smiths attempting to create a
better cutting blade. By repeatedly hammering a single side of the sword, smiths found they
could create a finer edge, and thus, a sharper blade. Because one side of the sword was made
longer than the other, the blade curved slightly. While at the time this was little more than a side

23

effect of the sharpening process, it would eventually become an integral part of the katanas
design (Turnbull, Katana: The Samurai Sword, 2010).
These initial curved swords, known as Jotoko Tachi, or Ancient Long Sword, were
constantly improved throughout the late Nara and Heian Periods (Nagayama, 1998). The rise of
the samurai class as elite mounted units necessitated a longer sword that would reach foes from
horseback and an even sharper, more curved blade. Such a curvature provided a mechanical
advantage over straight blades for cutting power and reduced the swords resistance when slicing
through a foe. This was particularly useful when fighting from horseback, as the forces generated
by a high resistance from the blade can knock the sword from a mounted combatants hand, or
even dismount the combatant altogether. Japanese sword smiths responded to this demand with
the Tachi, an intentionally curved blade roughly 85cm in length that proved dominant in
mounted combat (Morimoto, 2004). By the dawn of the Kamakura period, the success of the
Tachi made it a staple of samurai across Japan.

4.2.2 Emergence of the Stronger, Shorter Katana

The Mongolian invasions during the mid-Kamakura period prompted additional changes
to the Tachi as Japanese sword-makers confronted problems with their prior designs. Mongolian
swords were thick and sturdy, and many Tachi proved too fragile to withstand them. To fix this
flaw, Japanese sword smiths combined a thicker blade with improved metallurgical techniques to
create a stronger sword. In addition, the typically deep temper lines of the Tachi blade were
narrowed, as deep lines made the blade too brittle. The result was Tachis that were strong,
flexible, and razor sharp (Nagayama, 1998).

24

During the late Kamakura Period, as towns and cities grew and close-quarters combat
became more common, the Tachi was changed once again, reshaped into the legendary katana.
Designed for hand-to-hand combat, the Katana combined drawing the blade and slicing with it
into a single action, making it far faster than the bulkier Tachi. The katana was shorter than the
Tachi, measuring roughly 73cm long, which allowed for greater speed and maneuverability in
the often cramped spaces of urban combat. With these improvements the katana quickly became
the most iconic of the samurais weapons and a paragon of their fighting style (Turnbull, Katana:
The Samurai Sword, 2010).
The pinnacle of Japanese sword making, the Katana changed little after its inception
during the late Kamakura period. While the quality of the blade waxed and waned with Japans
inner turmoil, few distinct changes were made to the blades design. Names changed, with
swords from the Sengoku period being called Shinto, and those from the Tokugawa Period
Shinshinto, but at its core the Katana remained largely the same (Joly & Hogitaro, 1913).

4.3 Cultural & Religious Meaning

As was mentioned in the previous chapter, the katana held a special place in the hearts
and minds of the samurai. This section will examine this meaning within the context of the
samurais unique culture and religion. In addition, this section will examine the meaning the
katana held for the sword smiths who made them.

4.3.1 The Meaning of the Katana to the Samurai

From their Zen teachings, samurai learned to strive for perfection in their combat skills in
order to be as sharp and deadly as their blades. In a certain sense, therefore, the Japanese katana
was not merely a sword, but an extension of the soul of the warrior who yielded it and a
25

reflection of his skills on the battlefield (Nitobe, 1905). Traditionally, when a katana was made
by a master blacksmith, it was made with a specific personality that was meant to match that of
the samurai who had commissioned it. This personality could manifest itself in the length of
the blade, its width, its composition, in the fittings that decorate it and in other parameters (Joly
& Hogitaro, 1913). After a samurai received such a sword he was supposed to keep it by his side
for the rest of his life. The only exceptions to this were kanatas that were not made for a specific
person for combat purposes, but which were made as gifts or as ceremonial items (Joly &
Hogitaro, 1913).
This sentiment is the reason for still allowing the samurai to carry katanas after the rest of
the population was prohibited from doing so during the early Tokugawa period (Jansen, 2000).
In addition, samurai who sold their swords were considered to be extremely dishonorable. Some
samurai who had no choice but to sell their swords often sold only the blade and fitted the handle
with a wooden blade in order to make it seem as if they still had the full katana (Nitobe, 1905). It
is no wonder then that the end of the samurai era began in 1876 with Emperor Meijis
proclamation that samurai too could no longer carry katanas in public (Jansen, 2000).

4.3.2 The Meaning of the Katana for the Sword Smiths

In addition to having such deep meaning to the samurai themselves, the katanas also held
a strong meaning for the sword smiths who made them. Beginning with a period of prayer to
Buddha or the Shinto kami spirits, a blacksmith would embark on a deeply spiritual journey on
his own, personal path toward perfection when making a katana (Turnbull, Katana: The Samurai
Sword, 2010). The image on the next page shows how the sword smiths workshops was
sanctified using holy paper streamers as well as the presence of a botsudan, a small shrine for
Buddha and the kami. The smith and his apprentice are both wearing ceremonial white clothes,
26

which shows how strong the connection between the spiritual meaning of sword making and the
physical act of forging a blade was for these individuals.

Figure 3: Ceremonial Nature of Blade Forging.

4.4 Materials & Manufacturing Process

The katana has an anatomy that has varied from its earliest forms to its more recent
designs. The most common design observes a structure of hard, high-carbon steel jacketed
around an inner bar of softer, low-carbon steel (Kapp, Kapp, & Yoshihara, 1987). This gives the
katana the ability to hold its famous edge while being able to sustain usefulness throughout
combat. The tang, unworked throughout the process, is used as the focus around which the
handle and later the sheath are made.

4.4.1 Smelting the Steel

The first step in making a katana is making the steel, and for that, one needs a tatara. A
tatara is a handmade clay furnace situated over a large, pre-made structure of ash, clay, stones

27

and logs (Kapp, Kapp, & Yoshihara, 1987). It starts with a large pit being dug into the ground
that is upwards of 9 feet deep, 10 feet across, and 20 feet long (Kapp, Kapp, & Yoshihara, 1987).
In the middle of this pit, a small 2ft by 2ft drain running the length of the pit is dug and lined
with stones, dirt, and clay and covered with boards or stones (Martin, 2009). Next, the sides of
the pit itself are lined with large rocks and layers are put down starting with dirt and pine logs
followed by a layer of rocks, then layers of gravel, charcoal and clay. At this point, while the
layers are about halfway to ground level, three structures are built into the pit. The first two, as
seen in the picture below are air-ducts made with clay and rocks.

Figure 4: Tatara Furnace Schematics.

The last one will eventually become the base for the furnace itself, and that is a large
stone and clay pit filled with ash and charcoal. The white areas around these structures are filled
in with soil and the entire pit is topped with clay. This involved structure is important to the
28

production of the steel because it is imperative to keep as much moisture away from the furnace
as possible. The ash/charcoal pit directly underneath the tatara draws moisture directly away
from the tatara itself, and the air-ducts give the moisture someplace to go before heading down to
the drain (Martin, 2009).
Once the pit is finished, though, the tatara can be built in earnest. As stated earlier the
tatara is made by hand, so naturally its construction begins with 10 inch thick clay bricks set up
in rectangular shape of 15ft by 5-6ft. Its walls are built up to about 5-6ft high and coated with
more clay as mortar. The walls of the tatara are built around two lines of bellows pipes with
holes above each pipe to allow for direct observation of the smelting steel. Further, two holes for
slag run-off are built into the wall at the bottom of both walls of the tatara. A layer of charcoal is
added to the bottom of the newly made trough, lit, and allowed to burn down to ash to dry the
walls of the tatara (Kapp, Kapp, & Yoshihara, 1987).
Finally, the tatara is ready for production of steel. A new layer of charcoal is put down
and lit. Once it reaches the correct temperature, a layer of iron sand known as satetsu is added,
followed immediately by another layer of charcoal. This process of adding layers is repeated
every 30 minutes for 3 days straight. The furnace, burning at around 1500C, will burn off the
impurities in the 10 tons of iron fed to it while adding carbon from the burning of 13 tons of
charcoal, leaving steel behind. At the end of the third day, the walls of the tatara are torn down
and a 2.5 ton block of steel known as a kera is left behind. The kera is broken into chunks and
inspected by hand for quality. About half of this block is considered tamahagane, or steel that has
a carbon content ranging from 0.6% to 1.5%. Of that, about two-thirds will be ideal with 1.0% to
1.2% tamahagane. The rest can be used by combining pieces of low and high carbon steel to get
the carbon content closer to the ideal. The half of the kera that is not tamahagane can also still
29

be used, but it must be run through a different forging process to add or remove carbon from it
before it can be used in the construction of a sword (Morimoto, 2004). The image below shows a
tatara in action, making tamahagane by firing iron ore and charcoal.

Figure 5: Tatara Furnace Burning Iron into Tamahagane Steel.

4.4.2 Forging the Katana

Once quality is determined the tamahagane to the swordsmiths who inspect the pieces for
themselves and pick which pieces to use to forge the high-carbon outer jacket, and which pieces
to use for the low-carbon core. A typical swordsmith hammers down and breaks up the
tamahagane into flat squares of about 1 inch square and about inch thick (Kapp, Kapp, &
Yoshihara, 1987).

30

Figure 6: High Carbon Tamahagane Steel Squares.

These the smith puts onto a steel plate he made attached to a handle, covers it in paper
and clay to keep them together, and heats the entire bundle to around 1300C to weld the pieces
together. After the pieces are welded, the smith will begin to hammer the metal into a longer
bar, occasionally covering the metal with clay and straw-ash to keep from losing too much
carbon to oxidation. Eventually he will fold the result in half and begin again, forging the two
layers together and stretching the metal out. After about six or seven folds, the smith will cut the
metal into 3 sections and set them aside (Kapp, Kapp, & Yoshihara, 1987).

Figure 7: Hard Steel Shell Initial Block Formation.

31

The smith will then take four of these sections and repeat the original process. Once he
has folded this new set of steel together about 6 or 7 times, the smith will set it aside, and begin
work on the core steel. The swordsmith selects a 2-lb chunk of tamahagane that has a carbon
content around 0.5%. Instead of using the same technique as the jacket steel, though, he will
simply hammer this steel into a flat bar that he folds as many as ten times. What is left is a
narrow bar of steel weighing about a quarter of what it started at. He next takes the high carbon
steel from earlier and forms it into a 15-in long U shape (Kapp, Kapp, & Yoshihara, 1987).

Figure 8: Formed Soft Steel Core to be Inserted into the Hard Steel Jacket.
The low carbon bar is then placed inside the U and the whole bundle is heated to 1300C
or higher. The swordsmith hammers the steel so that the hard-steel jacket completely envelops
the softer core. A mistake at this stage could potentially destroy the sword at the later stages, so
the swordsmith must be careful in his work (Morimoto, 2004).
Now the swordsmith works on shaping the swords blank. The smith will lengthen the
newly wrapped steel until it is at about 90% of its desired length (Kapp, Kapp, & Yoshihara,
1987), as can be seen below in the comparison between a blank and a final katana.

32

Figure 9: Blank, 90% of Desired Length, vs. Fully Shaped Blade.

Heating in patches of 6 inches, he will work on forming the edge and ridgeline of the
sword, being careful to keep the sword almost completely straight while he does so. Once the
blank is finished, the smith uses a draw knife called a sen to shave off any irregularities and
unevenness on the surface of the metal (Kapp, Kapp, & Yoshihara, 1987).

Figure 10: Shaving Off Irregularities in the Blade.

The back and edge of the sword are filed down and evened out before the entire sword is
ground with a rough carborundum stone (Morimoto, 2004).

4.4.3 Final Quench

When it comes time to perform the final quenching of the sword, the smith coats the
sword in clay; thinly along the edge but thickly along the back of the sword. Because of steels
structural qualities, its primary form of hardening is by cooling down from a high heat. The
33

speed at which this cooling takes place affects the form the steel takes. The thinly coated area of
the cutting edge will cool quickly from the roughly 900C to form martinsite, which is a harder
form of steel than its natural austentite. If cooled slowly, as the portion of the blade with a
thicker layer of clay will, it will form into ferrite and pearlite. This quality of steel allows
swordsmiths to make the defining mark of a good katana; the hamon. The hamon is created by
taking advantage of the effects layered clay has on the cooling speeds of steel. Designs written
into the clay will often form a distinct difference in the form of the steel that, with polishing, will
become visible as the hamon line (Kapp, Kapp, & Yoshihara, 1987).

Figure 11: Covering the Blade with Clay for the Final Quench.
Once coated, the sword is heated evenly to over 700C. It is very important that the sword
be evenly and uniformly heated, because differences in temperature can be fatal to the sword
when it is quenched. Once heated, the sword is plunged into a trough of water where the cooling
curves the sword and makes the distinctive changes in the steel (Morimoto, 2004).

34

Figure 12: Quenching of the Blade in a Trough of Water.

The blade is then cleaned of the clay and the edge and curvature are given slight fixes if
they need it by heating small portions of it at a time and using gentle hammer strokes (Morimoto,
2004).

Figure 13: Adjustments to the Final Blade via Gentle Hammering.

The sword is now technically finished, though it looks nothing like the stereotypical
samurai blade, glistening with its hamon and reflective sides. The smith will now take the sword
and begin to polish it. Using a grinding wheel and polishing stones, he will clean the lines of the
35

sword, grind down and sharpen the edge, and generally prepare the sword for the next stage of
polishing. This is also the stage of the sword where any decorative grooves are added. The
process of making grooves can take as many as two days and requires the application of specialty
tools such as U-shaped drawknives, round files, and small polishing stones. Once this is finished,
the sword is sent for final polishing and handle fitting (Kapp, Kapp, & Yoshihara, 1987).

4.4.4 Constructing the Handle & Sheath

The handle and sheath of the katana are traditionally made from the same piece of
magnolia wood, or other expensive woods. Both are cut, finished and lacquered as part of the
same process (McDonald, 2002). Beginning with a single piece of wood, the general shape of
the combined handle and sheath is carved out. The sheath is curved, to match the curve of the
blade, but the handle can be straight or curved depending on taste. Most katanas were made with
curved handles that matched the curve of the blade, since the continuous final shape of the sheath
and handle was considered to be very beautiful (Joly & Hogitaro, 1913). This single sheath and
handle piece is then bisected along its length and the handle is then separated from the sheath.
Once the blade is finished, the shape of its tang is carved out of the two handle pieces and
the shape of the blade is carved out of the two sheath pieces. The fit is of supreme importance at
this stage. The tang must not be able to move inside the handle, since the resulting vibrations of
the metal on the wood due to continuous use of the sword could shatter the handle in the
wielders hands. However, it should be possible to easily remove the tang from the handle for
maintenance without damaging the interior of the handle. Similarly, the blade must slide easily
into the sheath but must not fall out of the sheath unless it is drawn. There should also be enough
space for a thin film of oil covering the interior of the sheath, either from oiling the sword during
maintenance or from a built-in oil distribution in the sheath (Kapp, Kapp, & Yoshihara, 1987).
36

After the shapes of the tang and blade are cut into the handle and sheath pieces, the pieces
can be glued together and their final, smooth shape can be carved and grinded out of the wood. A
hole is then drilled at a slight angle through the handle, to match the hole in the tang. A peg is
then inserted into the handle, through the tang, to secure the handle around the blade. The angle
makes the pegs fit very snug, such that it does not slip free unless pounded on (Kapp, Kapp, &
Yoshihara, 1987).
The next stage in the construction process is decorating the handle and sheath. Usually,
the sheath is lacquered and painted while the handle is wrapped with stingray skin and silk cord.
However, styles and fashions introduced a great variety into this final stage of the katanas
construction. Sheaths were therefore sometimes wrapped with stingray skin and silk cord as well
and handles were sometimes just lacquered and painted to match the sheath, without being
wrapped. For lesser swords, it was not uncommon to leave the handle and sheath as bare wood,
ground smooth and oiled but otherwise untouched. After this step, all that remains is to fit the
blade with a cross guard and decorative, metal finishing (Joly & Hogitaro, 1913).
The next section describes the process of wrapping the handle and the advantages of this
process over other styles of handle finishing.

4.4.5 Wrapping the Handle

As mentioned above, styles and fashion governed many of the customs that were
developed regarding the finishing of the katanas handle. In addition, since the wrapping affected
the quality of the final sword, cheaper swords used different materials than more expensive
swords for this part of the swords construction.

37

Although any leather can be used to wrap the wooden core and any thread can be used to
wrap the final handle, the best known materials used for handle wraps are stingray skin and thick
silk cord (Turnbull, Katana: The Samurai Sword, 2010). Stingray skin, much like shark skin or
alligator skin, has nodules that give the surface of the skin a rough, scale-like texture (Joly &
Hogitaro, 1913), as can be seen on the next page.

Figure 14: Samegawa, Stringray Skin with Nodules.

From an aerodynamic perspective, these nodules allow the flow of the water to separate
around the stingray as it swims, allowing it to move quickly through the water, with little
resistance from the separated flow. For katana handle purposes, however, the nodules simply
provide a surface with high friction to the handle, allowing the wielder of the sword to maintain
grip even with sweaty hands or while wearing gloves (Turnbull, Katana: The Samurai Sword,
2010). The thick silk cord creates grooves in the handle that allow the fingers of the wielder to
settle into them and therefore enhances the grip as well.

38

The quality of stingray skin is measured by the unique pattern of the nodules of the skin,
their color and their hardness. Stingrays have a hard, white, ridged section on their back. The
more complex the pattern this hard section has and the larger and more uniform the rest of the
nodules are, the higher the quality of the skin. Stingray skins are naturally a grayish white, but
they can be dyed like any other leather. Traditionally, the skin used for the handle was bleached
white and the silk cord was blue, black or brown. However, other colors of skin and cord could
be used for different occasion or for different decorative purposes (Joly & Hogitaro, 1913).
The skin must first be soaked in water in order to make it pliable. An adhesive is then
applied to the handle and the skin is wrapped snugly around the handle. The adhesive does not
have to be strong and traditionally was simply a sticky rice paste. Once dry, after about 24 hours,
the skin contracts and grips the handle very firmly. High quality swords have a full wrap, with
the stingray skin covering the entire handle and no gaps. In lesser quality swords, however, only
panels of stingray skin are applied to the handle along its wide sides. The silk cord hides the
uncovered parts of the handle, such that the difference between the high quality and low quality
swords is difficult to spot (Nelson, 2008).
After the stingray skin is dry, the silk cord is wrapped around the handle. There are many
possible patterns for the wrap, depending on the purpose of the sword and how decorative or
combat ready the blade needs to be (Joly & Hogitaro, 1913). Most commonly, the plain, triangle
pattern of the combat wrap is used, with small or no variations. This pattern can be seen in the
image on the next page.

39

Figure 15: Tsukamaki Wrapping Triangle Pattern.

In order to make exact triangles, the cord must be wrapped very tightly in a precise
pattern. To help with this, rice paper panels and triangles can be applied to the handle in order to
help the cord settle into the correct pattern. This step is purely optional, however, since a talented
handle wrapper can form the triangle pattern accurately without it. During the wrapping process,
the menuki crest piece is inserted between the ties (Nelson, 2008), as can be seen below.

Figure 16: Menuki Insertion into the Handle.

After this, the decorative fuchi and kashira are fitted onto the handle. The fuchi merely
slips onto the handle and is held in place by the cross guard. The kashira, however, has a hole
through which the silk cord is tied as the last step of the wrapping process. Once this is done, the
40

sword is finished and can optionally be fitted with a decorative saego or mounted on a stand
(Nelson, 2008) as can be seen below.

Figure 17: Full, Mounted Katana with Wrapped Handle & Sheath.

41

5. Other Weapons of the Samurai

As a long blade, the katana could not be used in every single situation the samurai faced
in combat. As was explained in previous chapters, the samurai actually had several main
weapons they utilized other than the katana. This section describes the evolution of these
weapons and the materials that were used in their construction.

5.1 The Wakizashi

5.1.1 History of the Wakizashi
The wakizashi emerged between the 15th and 16th centuries, created as a short sword
companion to longer blades such as the tachi and katana (Joly & Hogitaro, 1913). Just as the
katanas shorter length made it better than the tachi for urban combat, so did the wakizashis
shortera length make it better for even smaller spaces such as indoors (Turnbull, Samurai
Warfare, 1996). The image below shows a comparison between a katana and the shorter
wakizashi below it.

Figure 18: Comparison Between Long Katana & Shorter Wakizashi.

This swords lighter weight and smaller size made it ideal for stabbing and thrusting,
making it popular as an off-hand and backup weapon alongside the katana, often used to deliver
42

the finishing blow to foes (Turnbull, Katana: The Samurai Sword, 2010). Samurai would
typically wear both, a combination known as daisho or big-little, both on and off the
battlefield. In fact, it was often customary that a samurai leave his katana at the door when
entering a restricted area, but maintain possession of their wakizashi (Joly & Hogitaro, 1913).
Furthermore, the blade was the most common instrument used to commit Seppuku, the samurai
suicide ritual (Nitobe, 1905). However, unlike the Katana, the wakizashi were never exclusive to
the samurai; merchants were free to carry them as well (Nagayama, 1998).

5.1.2 Characteristics of the Wakizashi

Physically, the wakizashi has many more variations than the katana. With a blade
between 30 and 60 centimeters long, the sword can be divided into two classes: the shorter owakizashi and the longer ko-wakizashi (Joly & Hogitaro, 1913). In general, the shorter the blade
the greater, the sharpness as there is less need to thicken the blade for strength. Thus, in many
ways the wakizashi can be considered a smaller, yet equally sharp version of the Katana.

5.1.3 Materials Used in the Wakizashi

In terms of materials, the wakizashi was usually forged of just the hard type of steel used
for the outer shell of the katana. However, some wakizashi blades were made out of a soft steel
core and a hard steel sheath, much like many katanas. This made the blade much more expensive
and was generally considered to be a step up in quality, although it did not do much to change
the blades base sharpness or flexibility since its length was so small (Nagayama, 1998).

43

5.2 The Tanto

5.2.1 History of the Tanto
The tanto is the oldest of the three common blades used by samurai, a traditional
Japanese dagger dating to back to the Heian period. The Tanto has had many names over the
course of history and has changed lengths rather dramatically. However, it was always
considered to be a short, stabbing weapon used for close combat and self-defense (Joly &
Hogitaro, 1913). Initially, the tanto was used as a companion to the tachi, the long sword
intended for mounted combat. This pairing mirrored the later katana/wakizashi set, with the tanto
being used for close quarters combat and for finishing a kill. There are even records of the tanto
being gifted alongside a tachi or a katana to a prominent lord during the Heian period,
showcasing its importance to the samurai at the time (Joly & Hogitaro, 1913). As the tachi lost
prominence to the katana, the tanto still remained a staple of samurai armament, though its role
in combat was greatly reduced. Though for a time it was common to see a samurai with all three
blades (Turnbull, Katana: The Samurai Sword, 2010), the tanto was eventually relegated to use
by the lower classes, particularly as a method of self-defense for women (Joly & Hogitaro,
1913). A typical tanto can be seen below.

Figure 19: Example of a Tanto from the Kamakura Period.

44

5.2.2 Characteristics & Materials of the Tanto

Unlike the curved katana and wakizashi, the tanto retained the straight blade of pre-Heian
swords, and was either single or double edged. Furthermore, the 15 to 30 cm blade was designed
for stabbing instead of cutting, possessing a thick blade for maximum penetration (Joly &
Hogitaro, 1913). Constructed from a single type of steel, the tempering process used ensured the
tanto was just as sharp as its katana and wakizashi companions, such that it could even be used
for beheading to confirm a kill (Turnbull, Samurai Warfare, 1996). However, its small size made
the blade exceptionally tough and far better for penetration than either the katana or the
wakizashi.

5.3 The Bow

5.3.1 History of the Bow
As previously mentioned, the early samurai depended heavily on the bow as their primary
combat weapon, which was fired from horseback. Due to the height of the horse, the katana was
not as effective a weapon for the mounted samurai, since the mobility of the horse means that
they could move across the battlefield while remaining at a distance and continuously firing
accurate shots into enemy troops (Turnbull, The Samurai Sourcebook, 1998). Early samurai
battles often involved an archery duel between the samurai on either side, before the armies
closed to close combat (Turnbull, Samurai Warfare, 1996).
However, since the armors of the Nara and Heian period were bulky and reduced the
samurais mobility, they limited the range of possible firing angles, and often interfered with
drawing and releasing the bow effectively. In addition, the bow had only offensive capabilities
and had to be discarded in favor of other weapons once a charge into enemy lines was needed
45

(Turnbull, Samurai Warfare, 1996). Nevertheless, due to the samurais unmatched skill with the
bow and advances in armor development that allowed greater mobility, the bow remained the
main weapon of the mounted samurai for almost four centuries before eventually being replaced
by the spear (Turnbull, Samurai Warfare, 1996).

5.3.2 Characteristics of the Bow

The Japanese bow has a distinctive shape that is almost unique in the world. While most
bows are symmetrical around the firing point, so that there is an equal amount of wood above
and below the area where the arrow is placed, the Japanese bow takes a different approach.
Because the bow was designed to be used from horseback, there was a limit to how large the
bow could be to still be used effectively, but a lack of heavy woods such as were used for
European bows meant that the bow had to be large to distribute the forces involved in accurately
firing an arrow to long distances. Therefore, instead of creating symmetrical bows the samurai
used bows that were fired from only a third of the way up the bow, while the remaining two
thirds were above the firing hand. This made the bows very long, around 6 feet in size, but still
able to be fired from horseback. This structure gave it the strength and resilience that was
required for combat (Turnbull, The Samurai Sourcebook, 1998).
Like its unique shape, the Japanese bow also had a unique method of drawing. While
most European archers would hold the bow at chest level and then draw the string and arrow
back, the Japanese held the bow above their heads, perpendicular to the ground. They then drew
the bow string out as they pulled their arms down, so that when the bow was fully drawn it was
at shoulder level. This was done to avoid hitting the horse while drawing the long bowstring. The
image below shows an example of a person beginning to draw a Japanese bow by holding it
above his head, as can be seen on the next page (Turnbull, The Samurai Sourcebook, 1998).
46

Figure 20: Drawing a Japanese Bow From Above the Head.

5.3.3 Training with a Bow

In order to train the samurai in the art of being able to hit a target from atop a moving
horse, competitions based around horseback archery were created. This type of training regimen
is still practiced to this day and is known as yabusame, a type of competition that often takes
place at festivals. An example of a challenge at these competitions is illustrated in the image on
the next page, which shows a samurai firing at a small, stationary target from horseback
(Turnbull, Samurai Warfare, 1996).

Figure 21: Archery Training via Competition Challanges.

47

5.4 The Spear

5.4.1 History of the Spear
In the early days of samurai warfare, before the 14th century, the ashigaru were the main
spear-wielders (Turnbull, Samurai Warfare, 1996). The spears, known as naginata, were
considered to be graceless, inaccurate weapons and the ashigaru, who used them primarily to
stop samurai cavalry charges from the front lines, were considered to be disposable (Turnbull,
The Samurai Sourcebook, 1998). The more noble side of the naginata was its expert use by
samurai women, who were as well trained with the naginata as samurai were with the katana,
which was forbidden for women to use (Nitobe, 1905). However, around the Sengoku period a
shift took place in the role of mounted samurai. Instead of being archers, the samurai transitioned
to using a lance like European knights, sacrificing range for the ability to make a devastatingly
accurate charge. This lance was known as the yari and was based on its predecessor, the
naginata, but was much longer (Turnbull, Samurai Warfare, 1996). The shift to cavalry charges
also forced the spears of the ashigaru to adapt as well. The naginata of the past was relatively
short and thereffore extremely ineffective against the longer lances used by the mounted samurai.
Therefore, from the Sengoku period the ashigaru started to use the same spear as the mounted
warriors, to give them a fighting chance against the lances range (Bryant & McBride, The
Samurai 1550-1600, 1994).

5.4.2 Characteristics of the Spear

The naginata was composed of a shortened sword blade attached to a lacquered shaft.
This allowed for a cutting edge, at the sacrifice of stabbing strength. Often thought of as the
Japanese equivalent of the glaive, it was a versatile weapon. The yari, the Japanese lance that
48

replaced the naginata, was much longer, often at least 8 feet long. While there were several
different lance tips, the most common was a steel point with a triangular cross-section (Turnbull,
The Samurai Sourcebook, 1998).
As time went on, the yari was lengthened even further, eventually reaching a length of
5.6 meters used by the troops of Oda Nobunaga, as shown in the figure on the next page. The
extra reach granted by the spear was offset by the difficulty in wielding it, but keeping your
enemy as far away as possible and discouraging the dangerous mounted charges was a priority
(Bryant & McBride, The Samurai 1550-1600, 1994).

Figure 22: Comparison of Spear Lengths based on the Army

(Latest to Earliest).

49

6. Armors of the Samurai

While the katana of the samurai was believed to be their soul, it was not their only
distinctive mark. The armors of the samurai were equally unique to each samurai, allowing him
to stand out from the crowd and be recognizable even from a distance. This was important for
any samurai who wished to be promoted for their performance (Turnbull, The Samurai
Sourcebook, 1998). Like the katana, the structure of the samurais armor evolved as time went
on. As warfare intensified in Japan, the samurais armors progressed from a lamellar scales
pattern to metal bands and eventually full plates.

6.1 The Helmet

The kabuto, or helmet, was easily one of the most striking parts of the traditional image
of the samurai. As mentioned before, the samurai wanted to be seen and distinguished from one
another and their helmets reflected this (Bryant & McBride, The Samurai 1550-1600, 1994).
They often had embellished crests on prominent display, or additional rivets and differently
colored lacquer designs. Some embellishments involved things such as buffalo horns made of
wood, or red suns painted onto the sides. In addition, while European helmets, such as those used
by knights, covered a good portion of the face in order to protect the head as much as possible,
the kabuto did not cover the samurais face. Face-covering armor existed, and was known as men
yoroi, but was rarely used. This face armor was more mask-like and was meant more for
intimidation than protection. Fierce visages were painted on the men yoroi, and sometimes
moustaches made out of horsehair were glued onto it as can be seen in the image on the next
page (Bryant & McBride, The Samurai 1550-1600, 1994).

50

Figure 23: Example of a Decorated Kabuto with False Hair.

It is interesting to note that the helmet itself went through little in the way of evolution.
The main part of the helmet remained a ridged bowl throughout the different time periods. Some
changes to the original shape were made over time mainly for greater comfort for the head, but
otherwise the helmet remained static (Bryant & McBride, The Samurai 1550-1600, 1994).

6.2 The Chest Piece

The earliest sets of samurai chest armor were based on a lamellar construction, as can be
seen in the figure in the next page, and were called keiko. Lamellar armor is constructed from
rectangular scales that are pierced through so that they can be tied together into a single suit of
armor. This type of armor had the benefit of being relatively light, since the structure alternated
between iron scales that covered vital regions and leather scale-like pieces. Each scale was also
lacquered to give the armor a polished look and provide additional hardening for the leather
(Turnbull, The Samurai Sourcebook, 1998).

51

Due to its simplicity, this type of armor is easy to create and maintain. Like most
examples of samurai armor until the 15th century, the keiko set all of its weight upon the
samurais shoulders. While this did allow for slightly greater mobility, it also made the armor
somewhat uncomfortable to wear for extended durations. Samurai always wore their armor while
travelling to and fighting on the battlefield, in order to cut down on the amount of baggage that
they had to carry separately. Therefore, comfort became a priority. Eventually, samurai began
tying the armor around their waist to shift some of the weight down, like backpacks with built-in
waist belts do today (Bryant & McBride, The Samurai 1550-1600, 1994).

Figure 24: Sample of Scaled, Lamellar Armor.

Before the 13th century, the main two types of armor that were used by samurai in Japan
were the yoroi armor and the do-maru armor (Turnbull, Samurai Armies 1550 - 1615, 1992). The
yoroi armor was heavier and boxy, designed to provide a mounted samurai with great protection.
However, it was also stiff and limited the samurais mobility while on foot. The samurai
therefore eventually transitioned to the more flexible do-maru armor style, which eventually
52

became the modern style known as tosei gusoku. The first step toward this change was shifting
more of the weight of the armor onto the hips, to make wearing it for longer periods even easier
(Turnbull, The Samurai Sourcebook, 1998).
The chest, known as the do, was the piece that changed the most over the course of the
samurais history. While beginning as simple lamellar armor, around the beginning of the
warring states period the idea of creating the armor out of bands of lamellar scales, or even a
simple rectangular piece, became more common. Using a unified set of bands allowed the armor
to have a varying width along the body, so that more weight could be transferred to the hips
(Turnbull, The Samurai Sourcebook, 1998). It also produced the look that is most closely
associated with the traditional samurai, with overlapping layers, as can be seen below.

Figure 25: Traditional Samurai Do-Maru Armor.

53

When the Europeans arrived their sets of plate armor influenced the Japanese armorers to
change the armor styles. In addition, the arrival of guns to Japan meant that samurai needed a
much stronger armor (Bryant & McBride, The Samurai 1550-1600, 1994). The most famous of
the styles created in order to counter gunshots was the Yukinoshota-do. The surface of this armor
was completely smooth to better deflect projectiles, with all of the lacing hidden under the
surface. The creators of this armor were so sure of its abilities that they provided samples that
had been tested quite literally in the line of fire. In terms of appearance, the Japanese became
greatly enthused by the look of the European breast plate. After the Europeans arrived in 1542,
more solid styles of do appeared within a few years which were obvious copies of the
Europeans style of armor. In some cases, actual pieces of European armor were incorporated
into the Japanese armor sets and were simply lacquer over. An example of the more plateoriented armor style can be seen below (Turnbull, Samurai Armies 1550 - 1615, 1992).

Figure 26: Example of Europe-Influenced Japanese Plate Armor.

54

6.3 Additional Armor

In addition to the kabuto and do, the two other main pieces of armor were the kusazuri,
the thigh guards, and the sode, which protected the shoulders (Bryant & McBride, The Samurai
1550-1600, 1994). Like the helmet, these also evolved very little. Remaining composed of bands,
likely for mobility, these pieces were often physically separate from the do. The sode eventually
became smaller to avoid hampering movement as hand-to-hand combat became more prevalent.
The last piece of armor that was considered to be optional was the kote, or armored
sleeves. Since this was the last piece of the body left uncovered, but would interfere with the
samurais abilities to use his bow and sword, it was used less frequently than the other parts of
the armor (Turnbull, The Samurai Sourcebook, 1998). An example of this piece and the sode can
be seen on the next page.

Figure 27: Example of Sode from the Edo Period.

The final evolution of samurai armor came during the peaceful Tokugawa period. As
suits of armor were no longer worn into battle, they became decorative pieces with many old
styles revived as artistic tributes. In addition, impractical designs of armors were adopted due to
55

their look. An example of this type of decorative armor can be seen below (Bryant & McBride,
The Samurai 1550-1600, 1994).

Figure 28: Example of a Full Piece of Edo Period Decorative Armor.

56

7. Constructions of a Sample Katana

Considering that making a true masterpiece of a katana can take several months, it was decided
that it would be more beneficial to manufacture a sword of a lesser quality that can be finished
within the time constraint of the project. The above research had showed that it was a viable
option to use the traditional method of inserting a rod of soft steel into a shell of hard steel and
form the result into the shape of the blade within a reasonable time frame. The plan, therefore,
contained the following steps:

Purchase the metal required for the hard steel shell and soft steel rod

Assemble a block out of each of the steels, one of high-carbon (hard) steel and the other
of low carbon (soft) steel

Work the hard steel block into the shape of a folded v

Insert the soft steel block into the v shaped hard steel block

Work both into a single welded block by closing the shell around the soft steel

Stretch the resulting block into the shape of a sword blank

Defining the shape of the blade from the blank and cleaning it

Covering the blade in clay and quenching it to obtain the required curve

After the following steps, the plan was to fit the resulting blade with a wooden handle, wrap
it in the traditional manner using stingray skin and silk cord and then fit it with traditional
fittings. These fittings could either be purchased, along with the other materials required to make
the handle, or they could be forges from any excess steel that was purchased for the blade.
Like most battle plans, however, this plan had to undergo many changed since the actual
process of making the sample katana replica was more difficult and involving than predicted.
57

Most prominently, a brittle failure in the hard-steel/soft-steel block during the blank making
process forced the team to switch to an emergency plan that could be completed within our time
constraints. Under the new plan, the blade was to be constructed entirely of hard steel, without
folds, in order to show what the remaining steps of the original plan would have looked like had
the blank not failed.
The full description of all the changes that were made to the original plan can be found in the
Process section of this chapter, following a description of the materials that were purchased for
the constructed replica. The final section of this chapter details the results of the process that was
used, as well as the material properties of a sample of the welded hard-steel/soft-steel block.

7.1 Materials Used

Originally, 5160 Tool Steel was selected as the hard steel for the swords shell, but it
turned out to be highly problematic. After a failed attempt to fold this steel once as a proof of
concept, it was discovered that the 5160 steel has a larger percentage of chromium than other
types of high-carbon steel, which makes it extremely difficult to weld it to itself unless one is
working with temperatures higher than 2000F. The following shows the properties of this steel.
Table 1: 1018 Steel Properties from the Manufacturer
5160 Steel Properties from Admiral Steels
ASTM A689 & A304
Standard Specifications:
Typical Composition:

C 0.56-0.64%, Mn 0.75-1.00%, P 0.035% max,

S 0.040% max, Si 0.15-0.30%, Cr 0.70-0.90%

Rockwell C 25-35
Typical Hardness:
A fine grain chromium alloy. It is produced with a hot rolled round edge ideal for flat
spring applications. Chromium aids wear and shock resistance and promotes better
heat treat penetration.

58

Since the facility used for the forging of the sword could not achieve these high
temperatures, 1095 Spring Steel was purchased as a replacement. 1095 steel has a similar carbon
content to 5160, but does not have any chromium content. The table below shows the properties
of 1095 Spring Steel, as stated by the manufacturer:
Table 2: 1095 Steel Properties from the Manufacturer
1095 Steel Properties from Admiral Steels
ASTM A568 (sheets) A830 (plates)
Standard Specifications:
Typical Composition:

C 0.90-1.04%, Mn 0.30-0.50%, P 0.20% max,

S 0.025% max, Si 0.15-0.30%

Typical Hardness:

As rolled: Rockwell C 15-45

The highest of the carbon grades, this is a continuous cast, fine grain, fully killed
steel (#5 or better). Material is low phosphorus, low sulfur, calcium treated to
enhance internal cleanliness. In the as-rolled condition, material is well suited for
abrasion resistant applications. In the annealed condition, the material may be cold
formed (hot forming suggested for critical bends) with excellent heat treat results.

For the soft steel, 1018 mild steel was used. Luckily, the facility was able to supply this
metal for the group with no additional cost. The following image shows the properties of this
steel, as rated by an online comparison site.
Table 3: 1018 Steel Properties from Online Source
1018 Steel Properties from www.onlinemetals.com
ASTM A568 (sheets) A830 (plates)
Standard Specifications:
Typical Composition:
Typical Hardness:

C 0.18%, Mn 0.60-0.90%, P 0.40% max,

S 0.05% max
Rockwell B71

As can be seen by the above information, the hard steel has almost eight times the carbon
content of the soft steel that was used.

59

For the katanas handle, a finished wooden core was ordered, since sculpting the core out
of wood would have been a very time consuming process. However, stingray skin and silk ito
cord were obtained separately in order to wrap the wooden core manually. The images on the
next page show the stingray skin and silk cord ordered for this purpose, in WPI colors:

Figure 29: Silk Cord for Katana Handle Wrap.

Figure 30: Stingray Skin for Katana Handle Wrap.

A cross guard and decorative fitting were also ordered, since machining them would have
been complicated and would have also added too much time to the construction process. These
fittings can be seen in the image on the next page.
60

Fuchi

Kashira
Cross Guard

Figure 31: Finishing for the Sample Katana.

The final budget can be seen in the table below:
Table 4: Final Replica Budget Breakdown

Item

Use

Price

5160 Tool Steel

Final blade

$86.88

1095 Spring Steel

Hard steel shell of blade attempt

$36.73

1018 Mild Steel

Soft steel core of blade attempt

$0

Wooden handle

Handle core

$19.99

Stingray skin

Handle wrap

$53.78

Silk cord

Handle wrap

$6.00

Fittings

Decoration & tight fit

$49.49
TOTAL:

$252.87

61

7.2 Process
Starting with the 1095 spring steel, three one-foot sections were cut and spot welded onto
each other to make a block that was 1 foot long, of an inch tall, and 1 inch wide. This block
was heated to orange/yellow in color then hammered down to produce a weld, as can be seen in
the image below.

Figure 32: 1095 Steel Forging.

It was then ground down to remove the minor imperfections like where the metal did not
overlap properly and then it was reintroduced into the forge a small section at a time. As small
pieces of the metal were heated it was hammered with the thin edge of the hammers to spread the
metal into a larger plate. This was widened to accommodate a block of 1018 mild steel that was
prepared in a similar fashion. Once the 1095 was widened enough that it could easily be
wrapped around the 1018, a tang was formed out of the end of the 1018 and the process of
wrapping the steels began. To ensure a steady fit, the 1018 was spot welded to the plate of 1095
62

before the metal bundle was placed into the fire. The image below shows the 1018 steel, held by
its tang, and the plate of 1095 steel that was to be wrapped around it.

Figure 33: Joined 1018 Steel and 1095 Steel.

Once the bundle was hot enough (orange to yellow in color) to allow for proper welding,
it was removed, hammered into a special device that assists in curving metal, and placed back
within the forge. This process was repeated several times along the length of the metal to ensure
proper welding. This method worked marginally well until one portion of the metal bundle
became too hot and cracked outward, effectively ruining the bundle. The image on the next page
shows the results of this brittle failure.

63

Figure 34: Brittle Failure of the Hard Steel/Soft Steel Blade.

In an effort to save time, resources, and to produce a viable example, it was decided to
reattempt the making of the sword with only a single type of metal, rather than two. Using the
5160 tool steel that was first purchased for the sword, a piece of material 3.5 feet in length was
cut and lengthened through hammering.

Figure 35: 5160 Blade Second Attempt.

64

The lengthening process was more aimed at defining an edge and a tang than adding any
more length to the blade. With the edge defined, the tip was given its distinctive taper, and the
tang was produced. Once finished with the initial shaping the entire blade was sanded down.
The images below show the grinding process as well as the finished, silvery blade.

Figure 36: Grinding the Sword.

Figure 37: Final Blade with Silvery Finish.

The blades edge needed to be thinned to between a 1/16th and a 1/10th of an inch, the
back of the blade needed to be uniform, and the blade needed to be free of major dents, divots,
and imperfections.
Once the blade was free of these things it was covered with refractory mortar. Refractory
mortar is a type of clay mortar that is used in high temperature applications and we felt that it
would do the best job of acting as clay for quenching. The image on the next page shows the clay
application process.
65

Figure 38: Applying Refraction Clay to the Blade Before Quenching.

Once the mortar was dry the sword was placed into the forge and it was heated evenly
throughout its length by being pulled in and out of the forge slowly, allowing the flames to reach
all parts of the sword. Once the metal reached the point of being non-magnetic (again, orangeyellow in color), it was plunged into a trough of water, as can be seen below, to try to induce the
rapid cooling intrinsic with the formation of the katanas well-known shape.

Figure 39: Quenching the Blade.

66

Sadly, the clay did not perform as intended. Although the blade was successfully
quenched and a slightly wavy hamon pattern can be discerned along its edge, the blade itself did
not curve. During the heating process it seems that the clay became detached from the blade,
such that almost all of it came off almost immediately when the blade was quenched. Despite
this, the blade itself was still usable for the next step fitting and wrapping the handle for it.
As was described in the traditional process for making a katanas handle, a wooden core
was used for our handle. Since this core was purchased separately from its fittings, it had to be
carved to fit them before the stingray skin could be applied. The image below shows the carved
handle with the fuchi fitted onto it.

Figure 40: Carved Tsuka Handle.

The next step was to size the same, the stingray skin piece to be fitted onto the blade. The
piece of stingray skin that is depicted above shows very bright, white Emperor Nodules, which
are considered a very classy feature of a wrapped katana handle. Therefore, the same piece had
to fit such that these nodules would show up between the triangles of the wrappings. The cut
same piece and the tools that were used to fit it onto the handle can be seen on the next page.
67

Figure 41: Cut Same Piece & Handle Wrapping Tools.

The next step was to wet the stingray skin and use watered down glue to adhere it to the
handle. To make sure the same stayed close to the surface of the tsuka handle, silk ito cord was
used to bind the entire handle tightly. This assembly was then left overnight to dry, so that the
stingray skin would have the time to shrink and, together with the glue, strongly adhere to the
handle. The following image shows the wrapped handle assembly.

Figure 42: Wrapped Handle Assembly, Left to Dry Overnight.

68

The next day, any excess same skin was trimmed from the sword and the ito wrapping
process began in earnest, as the following image shows. The final sword can be seen in the
Results section below.

Figure 43: Silk Ito Wrapping.

7.3 Results
In the end, the experience of making a katana blade using traditional or near traditional
methods turned out to be very difficult and time consuming. However, despite multiple failures
and a lack of experience with forging techniques, we were able to successfully make a blade and
fit it with a handle to form a final product. The final katana blade and handle thus created can be
seen on the next page from various angles.

69

Figure 44: Final Replica of a Katana.

Although it is not made of two different types of steel and is not curved, its forging
process was still representative of the methods that the old sword smiths had used.
In addition, a smaller version of the hard steel/soft steel blank was successfully forged for
the purpose of examining the effects of the forging process we had used. To check if this process
produced any serious benefits over standard forging practices, we carried out two different
hardness tests, in addition to taking pictures through an optical microscope.
Before we could do this, we needed to cut and mount samples of interest out of the small
auxiliary blank that was made. Mounting involves creating a plastic shell around the sample of
interest. In simple terms, the sample is placed on the bottom of a container, and the plastic mold
material, either in powder or solid form, is placed over the sample. At this point, the container is
70

exposed to high pressure and heat within a specialized machine, forming it into a solid piece, as
pictured below.

Figure 45: Etched & Mounted Blade Sample.

Once this is complete the sample surface must be flattened and any contaminations have
to be removed. Therefore, the mounts are polished using a polishing wheel and sandpaper. The
wheel is continuously kept wet to clear away the particle debris created through the polishing.
After polishing the mount with a rough sheet, successively finer papers are used in order to
smooth the surface, removing any scratches that may have been made by the previous level of
roughness. Finally, an extremely fine diamond surface is used to polish the mounts surface to a
mirror finish.
However, a highly reflective surface is difficult to photograph. Therefore, a process
called etching is used to exaggerate the outlines of the samples microstructures. There are many
different etchants, acids used to etch the surface, as some are better at accentuating specific
traits in specific materials than others. We used Nital, a 2% concentration of nitric acid in water.
71

This etchant is the most commonly used solution for steel, and is most effective at revealing
alpha grain boundaries (Buehler SUM-MET, 2004). This solution was applied to the surface of
the mounts for 30-50 seconds, and then washed off with ethyl alcohol. This produced surface
traits that were easily observable under the microscope, as shown in the pictures below.
The two hardness tests that we used were the Rockwell scale and the Vickers scale. The
Rockwell scale is a measure of the indentation hardness, and produces a dimensionless number
based upon the head used to create the imprint. For example, to test the hardness of a steel
sample such as ours, a 120 diamond cone, known as a C head, is used to create the indent.
(Rockwell Scale) Multiple readings were taken from different points on the sample and averaged
to create a more accurate reading. The Vickers microhardness scale is based on a much smaller
area than the Rockwell tests scale and involved using a microscope to place indentation and
then measure the size of the indentation to determine how deeply the machines diamond tip was
compressed given the level of force used. Based upon the indentation size, the hardness of the
material can be determined (Buehler SUM-MET, 2004). This, like the Rockwell scale, produces
a dimensionless number used to determine the relative hardness of the surface.
We performed the Rockwell test on our sample that represented the flat of the katanas
blade, as the surface is homogenous, and would not differ between different areas. However, we
performed the Vickers test on the sample that created a cross-section of the blade to measure the
hardness across the boundary between the 1095 steel and the 1018 steel. The results of the
Vicker hardness tests can be seen in the following graphs.

72

Vickers Hardness across Hard and Mild Steel Sandwich

800

600
500
400
300
200

Boundary

Boundary
100
0

19 38 57 76 95 114 133 152 171 190 209 228 247 266 285 304 323 342 361 380 399
Location of Sample (microns)

Figure 46: Vickers Hardness Results across Both Steel Sections.

Vickers Hardness Across the Boundary

700
600
Vickers Hardness (HV)

Vickers Hardness (HV)

700

500
400
300
200

Boundary

100
0
9

19

28

38

47

57

66

76

Location on Boundary (microns, crossing from hard to mild steel)

Figure 47: Vickers Hardness Results across the Boundary between Steels.

73

The first graph is based upon measurements across the sample, starting from the hard
steel, crossing the mild steel, and then crossing back into the hard steel. The second set of values
and graph was generated from small steps across the boundary between the hard and mild steel,
staring on the hard steel side and crossing into the mild steel. From the above graphs it is clear
that the hardness of the outer hard steel is far greater than the hardness of the inner soft steel
core. It is interesting, however, to see that the boundary itself is a particularly weak spot in what
is otherwise a gradual decrease in strength from the hard steel portion to the soft steel portion.
Optical microscope pictures were then taken to get an idea of how the grains within the
steel had been affected by the forging. These images can be seen on the next page, showing the
different grain formations across both boundaries.

Figure 48: Grain Images Above & Below the Soft/Hard Steel Boundary.

74

The main image of the soft steel wedge within the hard steel shell was taken at x5
magnification, while the smaller grain images were all taken at x100. The scale on the main
image is for 100 m, whereas the scale on the smaller ones is for 10 m. These images clearly
show the difference between the mild and hard steels and the boundary between them. The
differences in grain size between the 1095 and the mild steel are also visible, as smaller grains
mean that the material is tougher. The grains of the 1095 are much smaller than the mild steel,
meaning that the hard steel will hold a cutting edge for the katana, while the mild steel gives the
blade some give to keep the sword from being too brittle. These images also clearly display the
different phases within the steel. Phases represent the way that the steel hardens as it is heated
and have different properties. The phase diagram below shows the different phases and at what
temperature they form based on the carbon content.

Figure 49: Fe-C Phase Diagram.

75

The phases that show up in our steel are austenite, martensite, carbides, and ferrite. It
should be noted that martensite does not appear on the phase diagram, as it is technically not an
equilibrium phase, because it is formed from rapid cooling of the structure, as opposed to the
slow cooling that is expressed in the diagram. The 1095 steel has a carbon content of
approximately 0.9% to 1.02%, while the mild steel has a carbon content of between 0.16% and
0.29%. The outer shell is therefore composed mainly of austenite and martensite. Austenite is the
more common form of carbon steel, and the state in which most of the 1095 was in before
forging. Martensite forms when austenite is rapidly quenched, and is tougher than austenite.
However, it is also more brittle, and so a certain balance must be reached to avoid making the
blade too soft (too much austenite) or too brittle (too much martensite). (Wikipedia, Martensite)
The close up image of the boundary between the 1095 and mild steel reveals some
interesting phases that have formed. Close to the boundary, carbides, also known as cementite in
steel, have formed. These large structures come from a combination of carbon and a nonmagnetic material. Because steel becomes non-magnetic when heated to a certain level,
(approximately 950C) this cementite forms from the austenite and martensite close to the edge
of the 1095 steel as it was welded to the mild steel. This is in keeping with the phase diagram
above, and this cementite is formed as a part of our forging process. Interspersed between the
carbide structures is the martensite that the cementite was formed out of, with temperature
differences and carbon distribution dictating where the carbides were formed.
Finally, the mild steel is composed mainly of the ferrite phase of steel. This is a s lowcarbon state of steel, but it is generally far softer, as obvious from our Vickers hardness test. The
outer steels austenite and martensite phases are very strong, but the strength drops off at the
boundary due to carbides, and reaches its low point within the ferrite. The closer examination of
76

the boundary in the Vickers result graphs finds that the loss of strength is almost linear, as the
sample transitions across the phase diagram, with the exclusion of the weak boundary point.
To provide context for these results unforged stainless steel usually has a HV of 140-180.
Our sample is much harder. This remains consistent with approximate conversion of the
Rockwell values (Struers). The average Rockwell hardness rating for the flat outer hard steel
wall that was tested was 50C. This is notable because the standard Rockwell hardness of a piece
of unhardened 1095 is approximately 31C (Properties Carbon Steels). So in the process of
forging the sword, we managed to increase its hardness value to a level close to modern knives.

77

8. Conclusion
Throughout this report, we have studied the samurais culture and how it was tied to the
tools of their trade their arms and armors. We considered how the samurais role was shaped
by the times that they lived in, and how they chose to evolve themselves as time went on. The
image that rose up from this study was that of a peculiar contrast between deadly warriors and
men of art and poetry, between generals of war and spiritual, family oriented men. The samurai
remain a cultural icon of the Japanese, and are known the world over as the perfect union
between their contrasting natures. All of the weapons of the samurai also skirted this balance
between form and function, elegance and deadliness. Even the katana, their signature weapon,
was both a weapon of war and a spiritual icon. In our attempts to forge a sword in the same
method as the smiths of their period, we came to realize how difficult and demanding the
construction of a katana really was. The dedication and kill that went into the weapons that the
samurai smiths had created was the discipline that shaped the samurais spirit throughout the
medieval history of Japan, a masters craft that was perfected across generations to create a
powerful and versatile weapon. It is therefore amazing to experience the ancient transformation
of a block of steel into an implement of war under the force of our hammers and grinding stones,
following in the old smiths footsteps. Using modern material science methods of inspection we
also saw first-hand how the forging process these smiths had used centuries ago was innovative
and surprisingly refined. The famed katana strength is a direct result of their forging process,
which was able to generate an alloy stronger and more flexible than anything at the time. The
katana, therefore, much like the samurai who used it, it a true marvel of history.

78

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http://wiki.samurai-archives.com/index.php?title=Japanese_Swords
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Brynat, A. J., & McBride, A. (1989). The Samurai. Osprey Publishing.
Buehler SUM-MET. (2004). Science Behind Materials Preparation. Buehler.
Deal, W. E. (2007). Handbook to Life in Medieval and Early Modren Japan. Oxford University
Press US.
Farwell, B. (n.d.). The Encyclopedia of Nineteenth-Century Land Warfare: An Illustrated World
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Ferejohn, J. A., & Rosenbluth, F. M. (2010). War and State Building in Medieval Japan.
Stanford University Press.
Honjo, E. (1932). From the Tokugawa Period to the Meiji Restoration. Kyoto University
Economic Review.
Ikegami, E. (1999). The Taming of the Samurai: Honorific Individualism and the Making of
Modern Japan. Cambridge: Harvard University Press.
Jansen, M. B. (2000). The Making of Modern Japan. Harvard University Press.
Joly, H. J., & Hogitaro. (1913). The Swod Book in Honcho Gunkiko & The Book of Same Ko Hi
Sei Gi of Inaba Tsurio. New York: Charles E. Tuttle.
Kapp, L., Kapp, H., & Yoshihara, Y. (1987). The Craft of the Japanese Sword. Kodansha
International.
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Louis, T., & Ito, T. (2008). Samurai: The Code of the Warrior. Sterling Publishing Company.
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http://www.thejapanesesword.com/tatara
McDonald, D. W. (2002). Montana Iron. Retrieved May 2, 2012, from Tsukamaki Article from
JSS/US: http://www.montanairon.com/tsukamaki.html
Morimoto, M. (2004). The Forging of a Japanese Katana. Colorado School of Mines.
Nagayama, K. (1998). The Connoisseur's Book of Japanese Swords. Kodansha USA.
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from Macabee Knives:
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ern%20age6.pdf
Nitobe, I. (1905). Bushido: The Soul of Japan. New York: The Knickerbocker Press.
Ogju, S. (1999). Ogyu Sorai's Discourse on Government (Seidan): An Annotated Translation.
Harrassowitz Verlag.
Ratti, O., & Westbrook, A. (1991). Secrets of the Samurai: A Survery of the Martial Arts of
Feudal Japan. Tuttle Publishing.
Sansom, G. (1961). A History of Japan: 1334-1615. Stanford University Press.
Sansom, G. B. (1978). Japan: A Short Cultural History. Stanford University Press.
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Turnbull, S. R. (1996). The Samurai: A Military History. Psychology Press.
Turnbull, S. R. (1998). The Samurai Sourcebook. Cassell & Co.
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Turnbull, S. R. (2005). Samurai Commanders 940-1576.
Turnbull, S. R. (2010). Katana: The Samurai Sword. Osprey Publishing.
Van Goethem, E. (2008). Nagaoka Japan's Forgotten Capital. Brill.
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10. Figure References

1. Retrieved on 2012, 4/28/2012 from:
http://www.swordsoftheeast.com/theanatomyofajapanesekatana.aspx
2. Retrieved on 2012, 4/28/2012 from:
http://www.swordsoftheeast.com/theanatomyofajapanesekatana.aspx
3. Turnbull, S. R. (2010). Katana: The Samurai Sword. Osprey Publishing.
4. Kapp, L., Kapp, H., & Yoshihara, Y. (1987). The Craft of the Japanese Sword. Kodansha
International.
5. Kapp, L., Kapp, H., & Yoshihara, Y. (1987). The Craft of the Japanese Sword. Kodansha
International.
6. Kapp, L., Kapp, H., & Yoshihara, Y. (1987). The Craft of the Japanese Sword. Kodansha
International.
7. Kapp, L., Kapp, H., & Yoshihara, Y. (1987). The Craft of the Japanese Sword. Kodansha
International.
8. Morimoto, M. (2004). The Forging of a Japanese Katana. Colorado School of Mines.
9. Kapp, L., Kapp, H., & Yoshihara, Y. (1987). The Craft of the Japanese Sword. Kodansha
International.
10. Kapp, L., Kapp, H., & Yoshihara, Y. (1987). The Craft of the Japanese Sword. Kodansha
International.

82

11. Kapp, L., Kapp, H., & Yoshihara, Y. (1987). The Craft of the Japanese Sword. Kodansha
International.
12. Kapp, L., Kapp, H., & Yoshihara, Y. (1987). The Craft of the Japanese Sword. Kodansha
International.
13. Kapp, L., Kapp, H., & Yoshihara, Y. (1987). The Craft of the Japanese Sword. Kodansha
International.
14. Joly, H. J., & Hogitaro. (1913). The Swod Book in Honcho Gunkiko & The Book of Same
Ko Hi Sei Gi of Inaba Tsurio. New York: Charles E. Tuttle.
15. Retrieved on 5/2/2012 from:
http://www.sword-buyers-guide.com/tsukamaki.html
16. Retrieved on 5/2/2012 from:
http://www.zatoichi.de/katana_01/tsukamaki-e.htm
17. Morimoto, M. (2004). The Forging of a Japanese Katana. Colorado School of Mines.
18. Turnbull, S. R. (1998). The Samurai Sourcebook. Cassell & Co.
19. Joly, H. J., & Hogitaro. (1913). The Swod Book in Honcho Gunkiko & The Book of Same
Ko Hi Sei Gi of Inaba Tsurio. New York: Charles E. Tuttle.
20. Retrieved on 2012, 4/28/2012 from:
http://www.asrai.org/viewtopic.php?f=1&t=19714
21. Retrieved on 2012, 4/28/2012 from:
http://sakurajapanesewarfare.devhub.com/blog/671313-martial-art-archerykyudokyujutsu/
83

22. Retrieved on 2012, 4/28/2012 from:

http://samuraidave.wordpress.com/2008/02/17/momote-shiki-japanese-archery-ritual/
23. Bryant, A. J., & McBride, A. (1994). The Samurai 1550-1600. Osprey Publishing.
24. Ornate Kabuto, with menp from the collection at the Glenbow Museum, Calgary, Canada. Taken
by Ben W Bell, July 2004

25. Retrieved on 2012, 4/28/2012 from:

http://ookaboo.com/o/pictures/picture/12597482/Japanese_Samurai_Edo_period_1600s_t
rue_l
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Note: All other images in this report were taken by the team.

84

11. Table References

1. Retrieved on 2012, 4/28/2012 from:
http://www.admiralsteel.com/products/200/hr5160.html
2. Retrieved on 2012, 4/28/2012 from:
http://www.admiralsteel.com/products/200/hr1095.html
3. Retrieved on 2012, 4/28/2012 from:
http://www.onlinemetals.com/alloycat.cfm?alloy=1018

85

11. Appendices
Appendix A: Glossary
Name
Kanai

Type

Description

Geographical

The provinces around Kyoto, especially Yamashiro,

Locations

Yamato, Kwatchi, Izumi, Settsu, Iga, Tamba, and mi.

Light feet: infantry. Largely developed in response to the
Onin War, the Ashigaru became the backbone of all

Ashigaru

Personal Titles

daimyo armies in the 16th Century, especially after the

widespread adoption of the matchlock. Until the 1590s,
an ashigaru was normally a peasant who worked in his
home village when not on his lords campaigns.

AzuchiMomoyama
period
Bushi

Historical
Events

Personal Titles

1568 1603

Warrior.
Way of the Warrior. First recorded in the 16th Century (in
the Koyo Gunkan and other such works), the term Bushido

Bushido

Cultural Terms

has come to act as a blanket expression for the philosophy

and mindset of the samurai, in particular the ideals of
honor and bravery.

Chokuto

Weapons

"Straight Sword", straight single edge Janpanese sword

Chonin

Personal Titles

A class term for merchants and artisans, who figured in

86

below the peasants and above outcasts on the social scale.

Great Name; term used to describe the autonomous
Daimyo

Personal Titles

lords of the late 15th and 16th Centuries who exercised

personal authority on a multi-province, multi-district, or,
in some cases, multi-village level.
When A Katana and a Wakizashi are worn together in a

Daisho

Weapons

Do

Armor

Chest armor

Do-maru

Armor

Early foot-soldier armor

Emperor GoDaigo

Important
Individuals &

Individuals &
Families

Gendaito

Genpai war

Hakama

Heian Period

Jokoto

Emperor of Japan during 1318-1339

Families
Important

Fujiwara

pair this is called a Daiso.

One of the three powerful clans during the Heian period

who are descendants of the imperial family.

Weapons

"Modern Sword"

Historical

A conflict between the Taira and Minamoto clans during

Events

the late-Heian period of Japan.

Armor

Type of riding pants

Historical
Events
Weapons

794 1185

"Acient Swords"; refers to blades before 965 A.D.

87

Kabuto

Armor

Samurai helmet
Phonetic syllabary popular in and after the Heian Period,
though generally reserved for the common people and

Kana

Cultural Terms

women. Edicts and codes commoners were expected to

understand were often written in kana, as were popular
books and the like.

Kanji

Cultural Terms

The adopted Chinese characters that are used in the

modern Japanese writing system along with Kana.
Traditional long sword of the samurai. Renowned for its
toughness and cutting ability. The katana, or tachi,

Katana

Weapons

became prominent during the later Kamakura period,

although it was considered secondary in battle to the bow
and later the yari spear.

Keiko

Armor

Early Japanese lamellar armor.

Weapons

Block of Steel and Iron ontained after the traditional

making

smelting processes

Kimono

Armor

Long-sleeved robe. Traditional Japanese dress

Koto

Weapons

"Old Sword"

Kusazuri

Armor

Thigh-guards

Kera

Lamellar Armor Armor

Meiji

Historical

Restoration

Events

Armor consisting of hundreds of connected scales.

A chain of events that restored imperial rule to Japan in
1868. The Restoration led to enormous changes in Japan's
political and social structure.
88

Men Toroi

Armor

Important
Minamoto

Individuals &
Families

Ming
China/Dynasty

Naginata

Nara period

Nihon-to

Oda

Onin war

Important
Individuals &
Families
Weapons
Historical
Events

Face armor
One of the three powerful clans during the Heian period
who are descendants of the imperial family. The
Minamoto defeated the Taira and started the first
Shogunate.

The Ming Dynasty, also Empire of the Great Ming, was the
ruling dynasty of China from 1368 to 1644.

Japanese pole weapon similar to the European Glaive.

710 794

Weapons

"Japanese Sword"; refers to blades after 964 A.D.

Important

A family of Japanese daimyo who were to become an

Individuals &

important political force in the unification of Japan during

Families

the Sengoku period.

Historical
Events

A civil war that lasted 10 years (1467 - 1477).

Wave Man; a samurai without a master. Many samurai

were made ronin by the vicissitudes of the Sengoku
Ronin

Personal Titles

Period, and so formed the basis for many bandit groups

and outlaw bands that plagued the countryside into the
Edo Period. Though not employed by a daimyo, a ronin
was still entitled to wear his swords.

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Sakimori

Personal Titles

Defenders; the main military force in Japan during the

Nara period.
"One who serves"; the traditional warrior class of Japan

Samurai

Personal Titles

until 1876. While of obscure origins, the samurai emerged

as a powerful force by the 10th Century and after 1192
acted as the de facto rulers of Japan.
A decisive battle on October 21, 1600 which cleared the

Sekigahara,

Historical

path to the Shogunate for Tokugawa Ieyasu. This is

Battle of

Events

considered the unofficial beginning of the Tokugawa

Shogunate.

Sengoku Period

Historical
Events

Sengoku Jidai, The Country at War. 1477-1600. The term

Sengoku jidai is taken from a roughly comparable episode
in Chinese history.

Shinsakuto

Weapons

"Newly made Sword"

Shinshinto

Weapons

"New New Sword"

Shinto

Cultural Terms

Shinto

Weapons

Shogun

Personal Titles

Shogunate

Cultural Terms

Term used to describe the government of a shogun.

Sode

Armor

Shoulder-guards

Japans indigenous religion, based on the worship of

spirits.
"New Sword"
Military ruler of Japan; a shortening of seii taishogun, or
barbarian/rebel-quelling lord general.

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Tachi

Taira

Weapons

Traditional Japanese long Sword used before the Katana.

Important

One of the three powerful clans during the Heian period

Individuals &

who are descendants of the imperial family. The Taira

Families

were defeated by the Minamoto.

Important
Takeda

Individuals &
Families

Tamahagane

Tang
China/Dynasty

Tanto

Tatara

A famous clan of daimy (feudal lords) in Japan's late

Heian Period to Sengoku period.

Weapons

"Jewel Steel"; used as the primary material in a Japanese

making

sword.

Important
Individuals &

The imperial dynasty of China during 618 to 904.

Families
Weapons
Weapons
making

Traditional Japanese "Dagger"

Traditional clay furnace that is used to make kera (steel)

Important
Tokugawa

Individuals &

Family which ruled over Japan from 1600 to 1867.

Families
Tokugawa

Historical

Period

Events

Tosei gosoku

Armor

Wakizashi

Weapons

1600 1867

modern armor. Samurai armor styles that were banded

as opposed to scaled.
Traditional Japanese "Short Sword" or more precisely,
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"Companion Sword".
Yabusame

Weapons

Japanese mounted Archery.

Yari

Weapons

Straight heaed spear.

Yoroi

Armor

Style of samurai armor, mainly used by riding samurai

Yukinoshotado

Armor

Type of samurai armor. Specifically developed to

withstand arquebus bullets

Masakodo

Historical

Rebellion led by Taira no Masakado against the central

Rebellion

Events

government in 939.

Important
Oda Nobunaga

Individuals &
Families

Hideyoshi,
Toyotomi

Important
Individuals &
Families

Initiator of the unification of Japan under the shogunate in

the late 16th century.

A daimyo warrior, general and politician of the Sengoku

period who unified political factions of Japan.

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Appendix B: Collected Material Hardness Data

Rockwell Hardness Test values:
Test 1: HRC 41.1
Test 2: HRC 52.2
Test 3: HRC 56.1
Test 4: HRC 50.6
Average: HRC 50.0
To provide context, 55-65 HRC is a good range for high-quality steel blades such as
knives made of Hardened High Carbon Steel (Wikipedia, Rockwell).

Vickers Hardness Test Results:

Position on Sample (crossing)

HV

19

615

38

704

57

622

76

698

95

683

114

612

133

300

152

226

171

174

190

170

93

209

160

228

169

247

298

266

436

285

630

304

689

323

695

342

683

361

683

380

759

399

649

Location on Sample Boundary

HV

628

19

561

28

285

38

481

47

372

57

240

66

163

76

166

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Appendix C: Updating the Online Database Site

Since the previous iteration of this project used the Dreamweaver software to generate
the original website, we chose to do so as well. The first order of business was to design a
unified look for all the pages of the site in order to give it a slightly more professional and
streamlined look. For this purpose, we used Dreamweavers Template feature to create a
template containing the sites banner and navigation buttons, which could be applied to each of
the content pages. The following images show the two templates main that were used on the new
version of the site:

Figure 50: New Website Main Template with Sidebar Navigation.

95

Figure 51: More Spacious Template with Top Navigation.

The first template was used for general pages, such as the main page, the reports page and
other pages that had only a small amount of content. The second template was used on all the
pages that require more space to fit their large amounts of content. These include the map pages
for each region and the specific arms and armors pages. An example of a map with period
navigation at its top can be seen below.

Figure 52: Clickable Map and Navigable Time Periods Example.

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Each of the black labels in the above map is clickable and leads to the arms and armors
page for the specific area the label is associated with. This functionality is a carry-over from the
previous iteration of the site, but the size and quality of the maps have been standardized to
maintain the same look throughout the entire page.
As a final note the site as a whole is relatively low tech, using only Dreamweaver
features and HTML. However, some scripts and more advanced features were used in order to
enhance the site. For instance, in order to keep all the files associated with the templates in one
folder and to make the code slightly more general, a Javascript script file was placed in each subfolder that contains content pages. This script file tells the page where its root directory lies, such
that the site can always find its main directory and the templates folder therein. In addition,
special code was added in order to implement the opening lists, which unfold the lists of team
members in the Teams page and the listed reports per year in the IQP Reports page.

97

Appendix D: Katana Making Process Documentation

Please see attached video file.

98