A couple jigs I made to help in the process.
First a drilling jig, made from mostly aluminum and a 3/8" square steel ricasso clamping bar.
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/4A97177E-EFD5-4A68-9FEE-B64957494634_zpsy1yb1dvx.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/4A97177E-EFD5-4A68-9FEE-B64957494634_zpsy1yb1dvx.jpg.html)
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/E0C1E493-62A7-4D80-911C-FF0595FE9065_zpskky4dcio.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/E0C1E493-62A7-4D80-911C-FF0595FE9065_zpskky4dcio.jpg.html)
Second a guard clamp. Made from aluminum with a 1/2" steel round bar. I just used some 3/32 roll pins which are holding up fine so far (If they start to give I am going to replace them with thicker drill rod) It clamps a guard really well and you can just clamp the clamp in a vise.
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/D548B64C-6654-40B3-A633-79DBD108A552_zpsfvz4r4ui.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/D548B64C-6654-40B3-A633-79DBD108A552_zpsfvz4r4ui.jpg.html)
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/86AC600E-C406-4FB4-A95D-A8AD4AF9BCAC_zpstv5mdrzf.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/86AC600E-C406-4FB4-A95D-A8AD4AF9BCAC_zpstv5mdrzf.jpg.html)
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/09DD0F88-8FE5-4F07-BC42-5DDFBE401FEB_zpsnnnkjmsu.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/09DD0F88-8FE5-4F07-BC42-5DDFBE401FEB_zpsnnnkjmsu.jpg.html)
Handle transitions
I came up with a better method (better method for me at least) to get the handle slightly proud to the guard/spacer. The method is based on the principle that it is easier to sand two materials flush with each other (rather than to a scribed line) and also it is easier to sand a thin, flat material such as a spacer flush to a scribed line (rather than a bulky odd shaped handle).
First I fit and finished the guard to nearly final dimensions. Next, I fit a copper spacer and then scribed the guard outline on the copper . I took the copper spacer over to the belt grinder and sanded down to about .020 from the line on all sides.
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/E8C95049-A85D-4073-A4C6-7DA795458E0E_zps2ju3vpeb.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/E8C95049-A85D-4073-A4C6-7DA795458E0E_zps2ju3vpeb.jpg.html)
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/F06066D2-0975-4B88-96C0-0612DEBBADC2_zpstv0bcrrt.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/F06066D2-0975-4B88-96C0-0612DEBBADC2_zpstv0bcrrt.jpg.html)
Then I fit the handle material and scribed a line from the copper spacer to the handle material (and then removed the material in the normal course.
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/E3A185C9-A54B-494F-BF6D-92D1BDF373EC_zpsqr8lxsis.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/E3A185C9-A54B-494F-BF6D-92D1BDF373EC_zpsqr8lxsis.jpg.html)
Then with the guard, spacer and handle mounted I finish sanded the handle material to the copper spacer, (which left the handle material about .015 to .020 thicker than the stainless guard).
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/757DD871-2564-4E67-B262-9180E94FA986_zpslyiut8oz.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/757DD871-2564-4E67-B262-9180E94FA986_zpslyiut8oz.jpg.html)
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/64F60450-A871-43E5-9C66-A83CEA1EED08_zpsjpyb6tlr.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/64F60450-A871-43E5-9C66-A83CEA1EED08_zpsjpyb6tlr.jpg.html)
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/C59E7942-F4F7-46E8-BF94-0993F0E85798_zpsszfit04k.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/C59E7942-F4F7-46E8-BF94-0993F0E85798_zpsszfit04k.jpg.html)
Finally, take the copper spacer off and sand down to the scribed line. Now my copper spacer is flush with the stainless guard, and my handle material is slightly proud.
(http://i492.photobucket.com/albums/rr287/bjjanse/2012-10/84355C69-7A94-4255-A4F6-F08AF0D23154_zpszdlosvko.jpg) (http://s492.photobucket.com/user/bjjanse/media/2012-10/84355C69-7A94-4255-A4F6-F08AF0D23154_zpszdlosvko.jpg.html)
Very good tip Brad! Those spacers are not only for looks are they? They are built in templates.
I don't know enough to say exactly what Im looking at but I can say you put some thinking in to it. Nice knife too.
Great ideas!
And very nice knife!
Steve
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Potomac Forge
Member, W.F. Moran Foundation