Using a small pin punch peen along the top edges
of the guard as shown to ensure a good fit to the
tang, being careful not to peen too close to the
front face of the guard.
Peen quite heavily on the underside of the guard
finger notch so that the metal expands in the blade
notch forcing the guard forward and completely filling
Use a parallel square file with the underside
in contact with the tang ground off smooth - carefully
file the back of the guard flat after peening
in place is complete.
File away excess metal down to the level of the
tang and clean up the finger notch with your "Dremel"
In preparation for the handle material, in this
case jigged bone, which will be finished slightly
higher than the surface of the guard it is wise
to sand the guard up to 1200 grit, ready for buffing
once the handle is fitted. Two pieces of soft wood
are stuck to the tang with double sided tape and
very gently ground into the shape against the platen,
with this in position it stabilizes the knife when
sanding a narrow guard held against the disc sander.