glue and lathe
Pierre- find someone with a copy lathe. They can take the brush handles you have and copy it exactly.
I use G-Flex and it is 85-95 F all year long where I live. This usually accelerates the failure of glues. I have not had any problems with G-flex.
After flattening and cleaning both the wood and metal, I use a dremel or sandpaper to rough up the gluing sides. This gives the glue something to attach to, all the crevasses.
I use a cutting disc on the dremel to make a slot on the rivets holding the old handle onto the knife and then unscrew them to remove the handle.
I clamp the heck out of the stuff anyway! I normally use JB Quik Weld and have shaped metal liners and spacers w/o a problem, even when they got hot and sizzled when I dunked it in water. I will have to try the G Flex one of these days!
I use the Bosch Zirconium sandpaper which seems to take them both down at the same rate. It not, I use a little file about the size of a pencil but flat, that a friend gave me. I think it is meant for woodworking, but does the job on the rivets.
Originally Posted by NO ChoP!
I found that those rubber sanding blocks they sell 3" wide by 4" long, uses a 3x6" sheet, work well for sanding pins/rivets flush to the handles. I cut them down into smaller sizes, remove the little tacks used to hold the sandpaper in place and use those. Harder than the cork block I used and kept the pins nice and flush to the handle material!