Well, so far it's working out right. Just an update, unfortunately no pics of the progress. I'm kind of combining two things at once, but currently I am hand sanding the blade (almost done...ricasso is basically done, just a bit more to do on one side of the blade and the finishing strokes to blend it all). At the same time, my first try at fitting a guard is going well. It's about 90% done at this point, I just have to clearance a bit more at the ends of the slot to fit the radius from the tang to ricasso. The fit looks really good to my unexperienced eye. Nice and even. Definitely not perfect, but a snug fit for sure. I'll post some pics once that's finished. Next will be to drill the slot in the spacer and the hole in the handle block, and then index the spacer and block with pins to keep it all lined up.
I'll keep you posted. Oh, while I was working, there was a heck of thunderstorm just a mile or two north of the shop that blew through. I'm posting pics in the Around the Grinder area. Check em out.
--nathan