wow this took longer than i thought to download the 15 pictures in order and upload them but here it is, sorry for the delay.
and now direct from Richard J's email is the "rest of the story"
anyone has questions they can ask me in the thread but here is how i did it in a condensed version
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the block is super glue proof that the blade is clamped in. a swivel vise is handy for this step
i line up the factory cut end on the block and adjust accordingly so the slab covers the handle.
i trace out the area i need to apply glue in and stick the piece against the block while laying it in place at the same time. i have the slab cut close but leave plenty for final trimming later to be safe.
i rough up the tang with coarse grit cloth or paper and wire brush off with hand brush.
i glue up one side of slab and put it in place and hold until glue sets. i repeat for the other side.
after glue sets up i trim excess from handle and then go to sander for final profiling
to contour handles i lay tape across spine square and wrap around to bottom side of handle for both ends
i then sand on the contact roller holding the handle in place and checking results often to make necessary corrections.
[img]
http://i1110.photobucket.com/albums/h459/sar511/11.jpg[/img]
after getting all sections shaped i move onto a roll sander to round the edges before moving to the scotchbrite wheels.
[img]
http://i1110.photobucket.com/albums/h459/sar511/142.jpg[/img]
the scotchbrite wheels remove all scratches and leave a non slip texture.
[img]
http://i1110.photobucket.com/albums/h459/sar511/13.jpg[/img]
[img]
http://i1110.photobucket.com/albums/h459/sar511/12.jpg[/img]
Richard, I hope I got them in order for you, if you see something that needs to be changed just let me know.