The most common problem with epoxy is incorrect surface preparation. Commonly people think that they are supposed to roughen the surface to get good bonding. This is NOT the primary requirement. What you do need is to get the surfaces CHEMICALLY ACTIVE, CLEAN and SOLID. What you need to do is remove any weak surface material, remove any old surface material, and get the surface chemically clean.
It may be obvious, but natural materials like antler etc. sometimes have weak material in the center where you want to do your bonding. It does no good to use 2-ton epoxy and attach it to 2-pound handle material. You may need to extensively ream out a stick tang handle and use a lot of epoxy filler to get strength in the handle. In the case of some slab handles you may need screws or rivets to provide adequate strength. The natural material may be very weak when stretched and may delaminate if secured on only one side by bonding.
Less commonly known is the need for "fresh" surfaces when you are bonding materials. An adhesive works by linking to surface molecules of the two substrates in the joint. When a surface is created by something like cutting, the surface molecules are missing neighbors on one side. The surface molecules have a mechanically enduced chemical deficiency that makes them want to bond to other substances. This is a great surface for adhesive bonding. A big issue is that this deficiency (high energy state) goes away rapidly with time. Usually within hours the surface is significantly worse for bonding or painting. In the case of rolled or forged material you don't even have a good bonding surface right after fabrication. If you cut a material with a lubricated blade you also don't initially get a clean surface. This is why people sand surfaces before bonding. You are creating a new high energy bonding surface, not "roughing up" the surface. You need to remove the entire old surface, not merely put a bunch of scratches in it. Really rough sand paper is not needed either. In the aircraft industry they often use an etching process. You need to do your surface preparation within minutes or a few hours of bonding.
Another issue is surface cleanliness. You need to use a clean volatile solvent like acetone (not oily solvent like mineral spirits) or use clean detergent solution before you do your sanding. This prevents contaminating your surface as you create it. If you use a detergent to clean the surface, rinse it thoroughly with distilled water and dry it before sanding. Use fresh and clean sanding material and work in a clean area--really clean, put some paper down on your table. It may be optional to wipe the surface with acetone after sanding. You may just need to dust it with a clean rag. Think clean and fresh at every step. Of course you are preparing both the metal surface and the handle material surface. Both fresh and clean, clean, clean. Watch how you handle the material. You may want to wear gloves to keep hand oils off the the surfaces.
Lastly, be very careful about mixing your epoxy. Be very careful about getting equal amounts of the two components. Do not trust the dual syringes to do the job automatically. Make more than you expect to use so that proportions will be more equal. Stir the components like crazy. Transfer the epoxy away from the place you mix it before using. When I mix on a sheet of paper I scoop the epoxy to another spot before applying--the spot where I mixed it will have hardener-rich and resin-rich areas on the paper surface. Rub the epoxy into both surfaces before mating them. Save your epoxy coated mixing stick and cure it in the same area as your handle. If your mixing stick epoxy does not harden properly you know you have a problem with your finished product.
[This message has been edited by Jeff Clark (edited 01-31-2000).]