Construction Tips - U-Joint tang
Ever have to attach a pommel to a tang and have a problem getting it to lie flat on the butt end
of the hilt? Ever screw on a pommel and find out that it doesn't align to the shape of the butt end?
Well....here's a complex solution to both problems. Make a tiny U-joint -- a block of 3/8" square stock
works for me. Slit it on one end and then slit the other end at 90 degrees to the first slit. Make the
slits big enough to fit over the end of the tang and over a the end of a ground down bolt (1/4x20 typically).
Drill a couple of 1/8" holes thru the tang and slit combo and thru the bolt and slit combo and rivet both
with short lengths of pin stock. If you counter sink the holes, you can rivet the pins into the counter sinks
and then smooth off the entire joint. You now have a mechanism that automatically guarantees the pommel will
The next problem is the getting an elongated pommel to align with the handle (for those who use elongated pommels
and hate to grind away lots of material. Attach a bolt section to the pommel, make a connector nut (buy one
and turn it down) and a lock nut (again, just grind off the 'corners' between the flats (see below). By adjusting
the location of the connector nut on the bolt section attached to the U-joint and locking it in place with
the lock nut, you control when the pommel finally locks down on the handle, i.e., you can control the alignment.
Of course, you could just use spacer material that crushes a tad.....