Trying something new, now I need some help.

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Apr 3, 2015
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A gentleman at my church asked me to make him a Bowie knife a while back, and I finally got started on it yesterday. I went with a through tang design which is a first. I also added a brass guard and pommel, which is another first. I slotted the guard today and noticed ugly gaps on both sides of the tang. How could I fill the gaps without ruining the appearance of the knife? I’m open to any suggestions. Thanks guys
 
If the gap is just a few thou, you can peen around the slot. Some material will move and close the hole a little. Unfortunately it also dimples the face of the guard so you need to sand it smooth again. You want to do as little as necessary for both steps.
 
Here's a hack: Make a "collar" that will sit in front of the guard and hide those gaps. The rub is you'll need to make the collar with no gaps!

I'm not saying thats what this maker did as it can be dones for looks as well but here's the idea...if there were gaps on the guard "behind" this piece of copper they would be hidden. Itll move your handle back the thickness of the spacer which will cause problems if you've already fitted/drilled it, though...could take as long to adjust as just making another guard, IMO.
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