I recently acquired this really nice Yoshikane suji from another forum member and decided that it would be a good subject for a WIP/How To tread.
Before we get into the project itself I would like to give a little overview of my construction methods/philosophy. All my handles are constructed using an internal slotted dowel to reinforce the joints and to create an internal void for the tang (I slot the dowel on a table saw using a homemade jig).
This internal dowel extends to 5-10mm of the end of the ferrule. This minimizes the amount of wood you have to remove when you cut the tang slot. After squaring up the glued blank I then drill a 1/8Ē pilot hole in the center of the ferrule. The pilot hole serves two purposes. First, it gives me a fixed reference point while shaping the handle. Second, it provides a starting point for making the tang slot. If the handle has an end cap I also cut a dowel from the same piece of wood Iím using for the body of the handle. I use this dowel as a through pin to mount the end cap. This picture of a cross section (looking down) will show you what I mean.
Ok, lets get started. Hereís a picture of everything I plan on using (not counting machinery).