Leave the bolster glued in place - but clean off
any glue, etc. on the bolster front edge, the ricasso
and parallels, clamp up the knife as before with
the first bolster now at the bottom. Glue the second
bolster in place.
Back to the drill press still set up as before,
drill right through both sides of the bolsters -
removing burrs as before.
It is preferable to leave the first bolster glued
to the tang just in case your angles are slightly
out, this then serves as a drill guide and corrects
the drill angle as it passes through into the second
Clamp the tang in your vice against the bolsters
and using a pin punch tape them off from the inside
edge - clean off all glue, etc. Relocate each
bolster with drill bots and scribe around the
tang, bandsaw/grind this excess down to the line.
Pine the bolsters together and mark out and mill
down the excess from the rear.
NOTE: Pinning the bolsters together without
the tapered tang between them presents a problem
- proceed cautiously - two snuggly fitting rivets
about the length of one bolster thickness, lightly
tapped into the center of this sandwich works
Using an old vernier scribe a line ±1.5mm
wide around the inside edge of each bolster - set
up and mill down this area - depth isn't important.
This allows the bolster a far better fit to the
tang when riveted in place. This can also be done
with a cut-off disc on the Dremel.
To shape the bolster, superglue them to a right
angled mild steel block (cut from 32mm square bar)
cut slightly longer than the bolster - as shown.
Now drill through the top two rivet holes into the
block and tap in rivets to prevent them coming off.