Ok guys, sorry for the little reprieve. I had been traveling to Blade (which was awesome!!) Met so many of you peoples
Also i've switched from photbucket to imgur. Shouldn't mean anything for y'all, i just couldn't stand the archaic pace that crapbucket moved at......
So here is a bit of progress i've made since then.
Here i began to scribe and layout the holes and whatnot for the spacer. Decided to go simple and understated since the attention is going to be focused on the wicked carbon layup done by Big Rick!
Cutting out the spacers with the jewelers saw. I can get it fitted with very minimal filing with a good blade and saw.
Fitted!
So i took my original drawing and made a photo copy of the handle. Printed it out, cut it out, and layer it against the tang... Makes life easy
Then i glue the paper template to the handle block. as you can see there is some material that needs to be removed...
Then i grind my angle in which is pretty self explanatory. HOWEVER, not saying i did this.... but make sure your platen is square people! Or else you'll have one hell of a time down the road. I
"knew" a guy who did this and he wasn't very happy :grumpy:
See now the tang is aligned in the center of the block, so i trace it and find where i need to drill my holes.
Holes drilled! I use those long spiral twist drills... very technical procedure
Here is one of my sawzall blade broaches. Now i don't have a fancy broach made by Bump or Perry, although i wish i did, but i would not use it on carbon fiber because you
WILL destroy it. Carbon fiber is very keen at dulling blades. i went through 8 sawzall blades after things were all said and done....
And you just play connect the dots, in theory at least
Yup, thats good!
A tip on fiting tangs; coat your tang in sharpie and slide it in, where its catching will show up... I'm sure i picked that up somewhere here on the forum, probably from Wheeler i dunno
SO, after fiddling around with this for two and half solid days. I became frustrated with my progress and decided to make the
"MegaBroach9000" just look at its 9000 carbon hungry teeth of destruction!
(*sorry cold steel i have that patented)
And it did the trick.

Typically it takes me maybe 30min, at leisurely pace, to fit a handle. However this stuff was not having it!
Next time i work with carbon hopefully i'll have a mill and some quality carbide 6" long end mills....
SO here it is all fitted and profiled! yay!
Doesn't seem like much but stuff like this takes me awhile; from now on out it
should be smooth sailing.
I will more than likely shorten the handle just a tad... keep in mind i don't profile it to exact spec at this point so that i'll have some insurance later on.
Whelp thats all folks. Tomorrow i will clean up the fit, drill my pin hole, finish the guard face, finish the blade (hamon polishing etc..) and if all that goes well.... have it glued up!
thanks everyone for following along, its been taking me awhile and i do appreciate your generous attention spans

-Mark