Yeah, some of that stuff sounds pretty complicated and or difficult.... At this point, I don't care that it look particularly neat or classy and I know nothing about welding.
Does anyone make pommels that have a groove milled in them that can just slide over the end of a 3/16 or 1/4" tang and then secure to the tang by cross drilling and securing w/ transverse pins or screws? I don't have any way to mill a slot in a block of steel or brass. Or, you could just put a couple little steel scales on the end of the tang behind your handle scales to act as a counterweight I guess and secure them w/ screws or peened pins. I think the old smatchet pommel was that way.
Grinding the tang to a certain width, rounding it a little and them putting a die on it would probably be relatively easy, Hell, you could even just use a big heavy hex nut... I would really like to do somehting like this w/ this WWII knuckle knife replica I have. THe blade in it is complete crap, but the cast bronze handle is good enough. I would have to thread the end of the tang to use the handle...