Mike, sorry I didn't answer your question in the other thread!! The alternative method I was talking about is very simple, but tedious. It was told to me by a very well established maker.
All you do is instead of milling or drilling the slot to size and then soldering it on. You mill or drill it smaller than the required size. Then you buff one side so you can see the reflection of the file in the guard to help you keep the file at 90 degrees to the guard while you file the slot bigger. Check it constantly till the guard is close to fitting the blade, then stop filing. Then simply press the guard onto the blade. You'll end up with a perfect and gapless joint . Since you have a blued guard, you might want to use some two sided tape to tape some foil onto the guard shiney side up.This way, you'll not need to solder it and mess up the blueing. Take care! Michael
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"Always think of your fellow knife makers as partners in the search for the perfect blade, not as people trying to compete with you and your work!"