Fitting a guard to the tang?

[TRfromMT]

First time for me doing a hidden tang...

Planning a copper guard approximately 3/8" thick on a tang that is 1/8" thick. To fit the slot I plan to drill a row of 3/32" holes and file the inside carefully until it fits. I want to be careful not to roll the front edge or flare it by bad file technique. I'll use a file guide.

Question is if I might make life easier by back-drilling a series of holes, say 5/32" to cut away most of the material I would otherwise have to file? Holes would only be drilled about 5/16" deep from the back side of the guard.

Thoughts?

 

[Hengelo_77]

I drill one hole and use a jewelers saw. I find that easier then multiple holes.
Still use needle files after sawing.
From the back I remove material with my foredom

 

[Stacy E. Apelt - Bladesmith]

As Bart pointed out, removing material from the back side so you only end up filing an exact fit on the front 1/8" of guard makes it a lot easier. I make the back side 1/4" wide.

Be aware that copper is very gummy to drill, saw, and file. Brass and bronze work much easier.

 

[AVigil]

Watch this it has 2 parts

 

[john april]

that makes good sense in terms of efficiency. but it will be slightly less mechanically strong although soldering would rule most of that out. there is also the chance the guard face may not be exactly perpendicular, or 90 degrees to the centerline of the blade, which would cause problems fitting the handle material later.