Originally Posted by
Erik Tracy
...My first try was to use a wood filler/putty to build up the 'dented' area, but every time I sanded it down to be even with the rest of the saya, little tiny bits would flake off leaving an uneven edge. I eventually ended up using super glue in layers to build up the depression and sanded it back down smooth. It worked well, but took a couple of days of layering to build it up.
Another method would be to cut out the dented area with a razor knife, so that the area to be repaired has "square" edges. Then fill with putty or even put in a new piece of filler wood glued in.
Having a deep, square area to fill will prevent the flaking, since there is no thin edge to the fill.
Yours in Budo,
---Brian---