Thanks Darcy,
Here is the process I was using on these hunters. I am getting a tight fit on the guard and spacer, and then nearly finishing them to final dimensions.
Then I am getting a tight fit on the handle material to the tang, drilling the pin hole and making layout marks on the handle block for final deminsioning. I then use a process of the handle both off and on to remove material and do the final sanding of the handle while attached (but not epoxied to the knife). I do this attached to the knife primarily as it is easier to sand the handle while it is attached. Then I take everything apart and epoxy it up.