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DaQo'tah, I guess you are saying that your hole in the guard is not square, not that the hole is not centered. If it isn't square you may file a little more on the low side then fit it to the blade by hammering on the side. I make the tang graduated (tapered from back of the handle to the front or guard end). I fit the guard, by hammering, about 1/4" behind where it should fit then take it back to clean up the hammer marks. It will then be a press fit when pushed to the proper location.
To prevent this from happening in the future I like to "center punch" with a cold chisel. That gives me a line where the holes should be drilled. Then saw out the webs with a jewlers saw. Will's suggestion of using a file guide is to keep the slot square. A file guide is simply pieces of metal that are on each side of the guard that keep your file square to the guard stock. I made the first one using mild steel but soon ruined it so I made the next one using pieces of car spring full hard (no tempering). Still using it.
If I have confused everyone please tell me and I'll try to explain better.
Lynn
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