This blog will take you step by step through the process.
1) The Khukuri and hammer handle as they looked originally.
2) The horn grip of the Khukuri breaks off easily and the spare parts will be used for other projects.
3) Lay the blade tang on top of the handle to determine what length to saw it.
4) Use a crosscut mitre saw with the handle tight in a vise. Wrap a cloth around it so there are no teeth marks from the vise jaws. After that drill with a large metal bit a hole downwards. The hickory wood is very hard and has a tight grain so files are used to shape the hole and bevel the edges.
5) A wooden dowel is split with a chisel to begin making two shims.
6) Use a utility razor to shape the shims you need to center the blade tang into the oval hole in the handle.
7) Be careful to fine tune the shape of these two plugs with a needle file.
8) A waterproof urethane based glue is just fine to use. Put some scotch tape over glued area so the glue does not bubble out as it cures.
9) This Khukuri had bad sharpening damage from a previous owner. Took a bit of reconditioning by hand and a proper sharpening.
10) The hammer handled Khukuri is now complete.
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