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Once the blade and handle are fitting together satisfactorily,
finish cutting out the handle. Then, you can start on
the artistic part of the project. The temptation may
be to chuck a round over bit in a router, a quick swipe
of abrasives and call it done. If you're happy, that's
fine. However, the nicest handles don't just have rounded
corners, they have an oval cross-section, and I believe
it's worth the extra effort. Half-round rasps and files
are the tools for this task. To get a consistent shape,
pencil on a few guidelines and rasp a series of facets
rather than trying for the complete curve in one shot.
There are about four stages to each corner, so the complete
circumference actually gets worked at 16 angles. Sounds
like a lot, but it goes quickly and seems to be the
easiest way to get the desired shape without losing
track of the curve. Blend the different angles into
one curve and follow up with files and abrasives until
you have the level of finish you want. Use your hands
as well as your eyes to ensure that you're getting the
shape correct; if something feels wrong, even if it
means going back a stage, do it now because it'll yell
at you when the saw is done.
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