Update on William's knife. He just sent me pics of the finished knife. I'll put them up here and then add his description of what he did and my response to him.
"here is the knife, I sanded it with 400, 600, then 800 grit in the blade itself and used my belt sander to finish the handle. Once it was done, I made a kydex sheath and attached a belt clip to it. All in all it went well, and you can no longer see the handle crack."
Dear Will,
Thanks for sending the pictures of your knife. I've been anxiously waiting to see how it turned out. There are also several knifemakers on Trad Gang that have been waiting to see the finished product, so I hope you won't mind if I post the pictures there.
As you know, we did everything twice as fast as we should have. The epoxy should have had a chance to set completely before we started work on the handle. Before we even put the handle on, we should have tested the edge to see if it was hard enough, but not too hard and brittle. Unfortunately, we did not have time to proceed as we should have, but raced through things as fast as possible.
Still, I think we came reasonably close on the heat treating. I know we got the edge hard and think the tempering heat was fairly close. I'm interested to see just how lucky we were. Once you have the blade sharpened, try cutting some pieces of scrap rope. cardboard, slicing newspaper, etc. and see how good the edge is. If our tempering temperature was a bit too low, the edge may still be a little brittle. If we went a bit too high, the edge will not hold the sharpness as long as it should. It may be interesting to compare to one of your kitchen knives. At any rate, I think you have a very serviceable knife there.
I'd also like to give you a piece of advice, which you are free to accept or ignore. DON'T SELL THAT KNIFE!
Someone may offer to buy it, thinking that will encourage you. Believe me, you will some day wish you had it back to compare to your later work.
Thanks for sharing the pictures with me. I hope we get to spend some time together next year. I surely enjoyed the short time we had working together.
Best of luck.
Ron"