Thanks again for commenting guys. Don't have a lot of pics, these are the few others I took.
Handle assembly. I used 10mm lengths of 1/16" drill shanks for the pins anchoring the frame legs to the three piece ferrule. Didn't have a lot of room. The other dot in the ferrule is the head of one of two pins that hold the three pieces together so they can be shaped as one unit.
The frame is 1/4" thick 416 with a hole drilled through to accept the 3/16 diameter, 316 stainless finial. Once completely assembled and finished I grind the little slotted tag off the end of the finial and polish the dome that's left. The hole in the end of the blade is threaded and what the finial screws into. At this stage I took the guard off and profiled it on the bandsaw and then the grinder.
Once profiled I took the guard round to good mate Shawn McIntyre's to give it a bit of a smack to spread the ends and bend the arms down. Always gives Shawn a chuckle when he watches me belt hot metal. If your going to be laughed at it might as well be a master smith. I was careful not to upset the flats and slot in the guard.
Next is the jig I made to grind everything true again. The base has a micarta plug set in it which is a press fit with the slot in the guard. The plug and the bracing plate hold the guard like it's set in concrete.
This is the opposite side of the guard. I use a thick sharpie to mark the face of the timber and grind till I just start to take the ink off. I always double check with a vernier, but this method is very accurate and use it often on weird shaped pieces. Hope I've answered some questions or at least given you some ideas.
