- 1). Choose your blade and handle according to size, type of metal and the length of the tang. The tang is the part of the blade that sticks into the handle to increase the strength of the knife. If the tang is too short, your blade may fall out of the handle with strenuous use. The handle must be longer than the tang.
- 2). Choose the material you will use for the handle. Handles come premade or you can use an animal horn. Choose a sturdy material that is easy to work such as wood or antlers. Cut the handle to the desired size and shape.
- 3). Drill a hole in the handle end where the knife blade will be inserted. The hole needs to be close to the width and shape of the tang. Attempt to fit the tang into the hole. If it does not fit, enlarge the hole, or file off any small metal "burs" at the end of the tang.
- 4). Slide the guard up the tang so it is snug before inserting the tang in the handle. The guard is a small metal piece that goes between the handle and the blade to keep the knife from sliding in your hand. The guard must be properly fitted to the specific blade so it can slide on properly.
- 5). Place the tang into the handle all the way up to the guard. Fill the hole in the handle with caulk, while the tang is in the handle and the knife blade is oriented the proper way. Allow the caulk to dry for 24 hours, making sure the blade stays oriented correctly.
- 6). Scrape off the extra caulk around the blade or guard and make sure that the tang is firmly in place. If not, allow the caulk to dry longer.
- 7). Use sand paper or a rotary tool to shape, sand and smooth out the handle so it fits in your hand well.
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