Partial tang cutter. Help please.

[TallTom]

Hi all, I'm putting new handles on some old kitchen knives, the tang is partial but visible at the top edge.

I'm having trouble figuring out how to cut the groove, my initial thought was a circular saw about 4" in diameter, the cut needs to be 2 mm thick, can anyone think of another way? As I don't own a 4" table saw.
I
Here's a pic of the tang

Thanks.

 

[Macaroon]

Do it with two scales, and hollow the recess for the tang with a chisel, then glue and pin as usual. If you take a little care you'll not see the join where timber meets timber.

 

[TallTom]

Yea that was an option I was trying to avoid I suppose. But thank you.

 

[Macaroon]

I think that making that cut to shape the tang "blind" like that would be difficult to do accurately, and you need to be fairly accurate to get the stability. I'm sure there are folk here skilled enough to do it, but is the knife worth it if you can't do it yourself? If you use a wood with a fairly pronounced grain you'd never see the join and you can always save the sawdust from the cut to mix with epoxy and use that as a filler if need be.

 

[brancho]

I would suggest three pieces of material two scales and an infill pice that is as thick as the tang with infill having a contrast.

Look HERE for a tutorial but adapt the method to leave the top part of the tang exposed

 

[TallTom]

Oh nice idea, for the sawdust thanks.
The idea of using an infill will mean the grain will match up... Thank you both. I think I have what I need now.

 

[Jared]

Broaches are the hand tools to do it

http://www.bladeforums.com/forums/showthread.php/838734-Make-yourself-some-broaches