Straight grain cherry stock
Squaring the stock with handplanes
Used Dozuki saw to cut the bridle joint for the blade to fit into
Chopped out the waste with 1/8” chisel
Clamped my 6” Starret into the square to ensure it won’t slip
Drilled out two holes for the pins. I used a modern twist bit but then slightly angled the bit once through. This gave the hole a subtle ovality resembling antique drill bits. Then I shaped the cherry pins with a bench chisel.
Hot hide glue installation of pin
Everything trimmed flush. Make sure to check for square on all sides!
Marking out details
The coping saw makes quick work of this
Files to smooth out saw marks
Ps. A few things I wish I had done:
1. Left the blade about 1/4" proud of the top of the handle. This makes truing up easier later. In fact, I may trim the handle down a bit so that I can have at least an 1/8" for later if it goes wonky on me.
2. Saw the bridle joint from both sides of the handle. This would make a cleaner looking joint. (Refer to Bob's video above for an explanation.)