Rehandle of CS Kukri - WIP - input welcomed

[schmittie]

I have had a Cold Steel Kukri for a few years and I have to admit that there are many things I liked about it - forward weight of the blade, not so big I can't pack it easily, thick enough I can chop and baton, price was just right too! However, if you have ever handled one, you will soon realize, as I did, that the handle is actually a blister factory. This is the handle in question -

Here is what I did with it the other day -

As you can expect, I came across something that has stalled out my plans. The tang is too small to do an exposed tang handle, but much too big for me to do a hidden tang as I had planed on. I actually had some black Corian cut into a spacer that is the right width of the tang to wrap it in a spacer, but now I feel that is going to be a lousy idea for this chopper. There not enough space to pin the spacer if it just wraps around the handle and I think it would break too easily anyway. (am I explaining that well enough?)

With the holes already drilled in the handle, I think I would loose too much strength if I tried to grind it down smaller. Its dangerous enough as it is. I am a bit puzzled right now. I had considered not putting a wood handle on it and just attempting a leather stack handle, which I have never done. Or I guess I could try to do a twine wrap and epoxy soak, who doesn't want to be like Rick Marchand when they grow up? But again, I've never done that either.

In the meantime, I have begun sanding the paint off the blade-

In addition to a new handle, I hope to force a patina on the blade, or etch it and of course, regrind the edge. The factory edge is bogus.


Well, this is where I am right now. I know it is not nearly as interesting as many of the WIPs from bar stock or forging, but I would still appreciate your input. What would you do?

Edit: Sorry, forgot to mention the RED on the workbench is some old paint. Do not be alarmed, I did not cut myself!

 

[crimsonfalcon07]

You should actually be fine grinding it a bit flatter so you can do a hidden tang. Those holes aren't as bad as you'd think with regards to the integrity of the steel. I don't know what kind of tool setup you have, but if you have the time or tools, you might instead just try to copy the original handle and do some milling out there, or use some woodcarving tools to carve out the indent for the tang. Doesn't matter if you're a bit sloppy, because the epoxy (or acraglass if you have some) will fill up the gaps. Maybe countersink some big holes for the giant pins that go through the handle, use some piping or something for that. I'd probably just grind it down a bit and do a hidden tang rehandle, personally, though.

 

[GHEzell]

This looks to me like a very good candidate for a mortised handle.
http://www.bladeforums.com/forums/showthread.php/609271-mortised-handle-(for-Ryan)

PS.
A mill is a good way to do it, but not at all necessary. The same can be done with chisels, or a dremel-type tool.