Reddit reviews Bahco 1-111-06-1-0 Warding Cut 1-File, 6-Inch, 10-Pack

Allright, here goes.

What I would do is aim for [something roughly this shape](https://i.imgur.com/gwSfsSJ.jpg]

What I'd do is cut according to this sort of plan and use an anglegrinder with cut-off disc to chop the tang out (marked in red), then use a dremel (Marked in blue) for the fine cuts. I would then round off the shoulder of the blade with a round chainsaw file to remove the risk of stress raisers.

Once there, I'd use a Warding File to file in the little notch step down at the bottom of the tang, from a rough squared-out cut , to become a round circle along its length. That's going to become your Pein, when the whole thing is assembled.
I'd then put that pein part in a flame - ideally a blue gas flame, wrapping the blade in a damp cloth to ensure its not getting hot. you'll ideally want to get that part glowing red-hot. What that'll do is completely blow the temper on that part of the tang, so its no longer hardened at all. that'll let you pein it over later.

Then I'll take two pieces of steel, curved into arcs and I'll clamp them down, and start to drill the centre - that will depend on the blade of course, but what you want in effect is a slot, for your since its from a blade that's probably going to be a () shape, or maybe even a <> shape.

you'll use that warding file to slowly widen the drilling, taking it from two holes side by side into a rectangle, then widening it and shaping it to match the blade cross-section. Once that's done, repeat on the second one, to sit on the other end of the tang. For it, you will probably want to use a small 4-inch square-cut file to get that to fit. You want to use a square so that the pommel end guard doesnt swivel around at all.

that's then topped off with a little pein block which serves a double purpose - it makes it easier to repair if it ever has a problem (just file it off and put a new, smaller block on) and, as that part of the tang was filed round, you just need a drill to make a round hole, instead of a rectangular hole. (also a small pein is easier to do - just clamp in a vise and hammer over like a rivet. Having softened the metal by getting it glowing red earlier, you can probably do this part cold, so no torches needed.)

lastly, I'd then make a two-piece wooden grip, the bread around the tang in a sandwich, in effect, out of beech or similar hardwood (though poplar should do for that, and its easy to carve out the slot for the tang in.

I'd make that a bit thinner than you expect it to be - over-bulky grips are a common mistake - Glue it together, and wrap it in fine cord with hide glue and then I would follow this fantastic tutorial guide from Peter Johnsson to wrap a section of fine vegetable-tanned leather round it, wrap that in cord, and have a beautiful leather hilt at the end.