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I believe that Will is right on target here. Uncle Bill has stated too many times about the horn cracking because it was monsoon season in Nepal and high and dry in Reno causing the horn to crack. Even his beloved Ivory handle cracked because the knife wasn't kept in a humidor.
Out of the even dozen I have so far, 8 of them have horn handles. Out of those 8 only one has some minor cracking and I believe it is because the horn itself wasn't of that good a quality.
It is on one of the little 13" balance models and it has some color to it in the form of some greys and a bit of white and that's where the cracking originates too.
On the other hand Every one of them has shrunk due to the dryness that we have had the last few months here in Oklahoma. ( WE have had fire bans several times in the last 9 months because it has been so dry. Very unusual for here.) Like I have stated before I have taken a file and putting it at about a 45* angle filed the intersection at the horn and butt cap. I recently bought some new files and there were a couple of 3 cornered files in them that work wonderfully for the purpose with much better control. Some of mine had shrunk as much as 1/32" to a bit more on each side of the butt cap. I had to file the brass even with the horn before putting the groove in. It makes for a real nice looking fix and removes the burr from under the butt cap so even if it does shrink a bit more the edge is still nice and smooth and won't cut your hand.
Ghost was always right when he talked about the black horn being the strongest.
We may have brought some of this on ourselves because the striped horn is prettier and that's what we were wanting. I can just imagine Gelbu deliberately looking for the striped horn for HI's crazy American customers. I love the striped horn too, but will ask for the solidest black horn that Uncle has availible from now on!
You can bet that Uncle Bill will get to the bottom of any problem and will get it corrected. Not only that, he will exchange the knife for another one if we wish. I sure wish that some other companys would let me exchange a knife just because I didn't like the one I got. I would most certainly have returned a few by now and they sure aren't HI khukuri's!!
I have to face up to the fact that I like messing around with them anyway. What would I do if they were absolutely perfect? hehehe.
( Although there have been a couple that were. The Hanuman Special for one. How long does it take to polish one away anyway?)
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Khukuri FAQ