...by what method,, and with what tools...
Gosh, that was about 40 years ago when I was a teenager...
Lets see, I remember I had read an article (in Guns and Ammo probably) about how Randall made his knives, IIRC there was a picture of him staking a leather handle, I tought I could do similar with thin wood slices.
I remember making a jig, with a pressure plier and two nails, for turning the nut in the pommel.
There was a long piece of 3 mm plywood laying around my dads shop, it was already 3 mm thick (it was made from three plies 1 mm thick each) and about 2 inches wide, I cut up square pieces with a simple saw and then made a hole in the center of each piece with a hand drill, I moved the drill around to get it sort of oval to fit the tang.
I made a new guard from a scrap piece of aluminum, I should have kept the original brass as the new one has gotten loose over the years, but the handle itself is tight so I have left it alone.
I remember covering the blade with tape and holding it vertically, tang up, in a vise, pressure fitting the guard and pushing in each piece of plywood putting some contact cement (or was it epoxy ?) on each piece before putting in another one, let it dry till the next day and then using saw, rasps, files and sandpaper for shape and finish, I think I just waxed it then and years later put several layers of varnish.
Here's another (better) picture of it along with my short Kabar and my little Boker.
Luis
Click to enlarge