That last #$%^ 0001" of an inch HELP!

[RobertHankins]

I am now working on the third guard for my Latest Bowie. I get it fitted REALLY close, I mean just about to where I can drive it home and AAAAAAAAARG
Anyway what I keep doing to get that air tight fit must be wrong.
I wind up filing the sides of the slot thinking that will allow it to slip that last 0001" winds up with that less than a hairline gap on the sides... Ends toward the edge and spine are fine.
I am using a filing jig and filing on a slant toward the front of the guard to reduce the friction as I pound it home.

Somebody have some Pearls of wisdom to pass along?

 

[Chang]

Fit it on the knife, and hit it with a hammer a couple times, it will close the gaps slightly.

 

[Bruce Bump]

Yep what Chang said. I have closed up about 1/16" gap before with brass and a hydraulic press. This is also how Ive cracked that cheap gold colored so-called nickel silver. The trick really works on brass though.

 

[peter nap]

What the others said. A little hint though if you want it to look like it grew there. Get the fit really close but so tight it really won't quite slip on. Heat it with a torch. Not hot enough to change the color just enough to get it hot. It will expand enough to slide on and when it cools it will be a perfect fit.