[ImanCarrot]

Two stick so I can get a ful circle, yep.. that's my thoughts. Unless I can split the wood lengthwise, either by hammering a sharp blade down it's length or by hammering lots of them hand razor blades down the side wall, but I'm certain that I'd never get a straight split cos of the wood grain?

I plan to fixture it directly on to my mill table on the T slots which are true to my X travel. The walking sticks will, no doubt, be tapered so I was planning to use different height v- blocks along its length then thought "hang on.. the blade tapers anyway" so might not be a problem just clamping it to the T- Slots. I might need to hand finish the slot in the wood.

Ball nose mill is a good idea, thanks mate.. didn't think of that. Was gonna use an end mill. I'll end mill it out then ball nose it- more strength as you say.

If it warps? hmm... hadn't thought of that. Initial thoughts are putting the two halves together with the blade inside, using padded jubilee clips to clamp them together (without glue) and steaming the lot for two hours. Obviously would need to remove the varnish from the original walking stick halves. I could use a plastic drain pipe for a container connected to a kettle or something.

Is there any wood that doesn't warp a lot?

Or.. perhaps I could just mill a slot down the length of one whole stick. Put the sword in (greased), fill the slot with that putty stuff that sets like concrete, remove the blade and get a french polisher to add the wood effect on the filled slot.

Can't wait to pick em up.. getting them in two hours.