:thumbup: Thanks guys, I am waiting to receiver my first HI... a WWII model but I am already thinking about my next purchase which will be this Friday. I probably should wait to inspect the first one before ordering another but I think its a safe bet going with any of HI's stuff....
I ordered a 15in blade Afgan defender model for Ex-Gurkha house and I was less than impressed..... The handle is the worst part though... The shape is far from ergonomic and the three pins holding it together are just brass tubes filled with molten pot metal. After I purchases it I saw a "bare" blade with the handles off.... The wholes are twice the size as the pin holes. The only thing keeping the handle on is the glue, not the through pins on the grip....
You should wait to check out the first HI blade before ordering a second. Not because of quality issues, but the first one will give you a better idea about what length, weight and handle size is best for you.
You mention that the EGH Afghan Defender model at 15" is way too heavy. You might find that an HI blade of similar length is lighter weight because of the fullers, and better balanced.
On the question of the pins in the handles: Others might have other experience, but I've seen a few HI chiruwa-style khukuris with the scales off and I think it's normal for the holes to be wider than the pins, though not twice as wide. When the pins are hammered in from both sides, they widen up and fill the holes better, and of course they press the scales in place from both sides. Also, the laha that holds the scales on is extremely strong and grippy. Other than that, though, your comments on the Afghan Defender match what I've heard from others. By the way, I believe the HI kamis use solid aluminum pins, though a few models use a combination: a hollow brass tube filled with a solid aluminum tube.