I sure do appreciate the positive feedback guys. I really do want to get more into experimentation with textures, colors, curves, etc. I have lots of ideas.
It would be nice to be able to do more along these lines, but I'm just not sure if I can justify the time. One would think that doing something "rustic" like this would be faster and easier, but it's not. Not by a long shot.
It's a lot more time and work intensive than just slapping on a guard and handle roughly to shape, then refining everything at the grinder, like most of us do on a simple hunter.
Obviously I couldn't grind the handle down to the textured guard and finish it -- I'd be grinding on the guard and screw it up. So everything has to be finished and fitting perfectly before the final assembly.
That's one thing that made me think of hiding the pins under the inlay. When the handle went on, it was aligned with the finished guard by means of indexing pins that are hidden between the guard and handle. The slot for the inlay was already in place, but the inlay was not put in at that point.
Once the bonding agent had cured, two small holes were drilled in the slot for the inlay until I was through the tang, but before breaking out through the other side. The pins were inserted and tapped down with a nail set, then the inlay was inserted.
Of course I still had to carefully work down the inlay until is was flush, but that was only one point of possible screwup on one side. That's better than having the finished handle attached and having to deal with the the inlay and two visible pins. Since the two pins would have to be worked down on both sides, and the inlay on one side, I'd have had five different points that gave potential for screwing up.
Sorry for rambling. Too much coffee.
