My intention was to increase the thickness of the grip and provide more flat surface at the edge, while maintaining the original width, using a cord wrap over the core to add bulk under the new leather wrap. To maintain the original width it was necessary to narrow the wood core slightly by rasping the edges down to account for the thickness of the cord, this also helped to increase the flat surface at this area which I felt was lacking on the original grip.
Then I wrapped the core with a round imitation leather cord (not sure what it's actually made of, I have a bunch of it so I figured I'd try it out), securing the ends with super glue. I used the same cord to create the risers, one turn for the ends and two for the larger one in the center, again attatching them with super glue. Just for fun at the last minute I added one an inch towards the guard, placed to sit just under the edge of my palm when in a hammer grip.
Then I "scarfed" the edge of the leather I would be using, cutting a very acute bevel on the edge that would be the exposed seam so that on the outside it came down to a thin, feathery edge. The other edge I beveled also to help keep it from forming a line under the wrap. I don't remember where I got the leather, it was from a hobby store I think and was very thin black leather, like driving gloves are made from. I coated the leather and the grip with contact cement, started at one edge, and wrapped the leather tightly around the grip, until I had a roughly calculated 1/4" overlap on the edge where I started.
This I wetted and coated with Elmer's Nano-Glue, very thinly, removed the excess, and pusehd the edge down, wrapping it over tightly with food wrap for about 45 minutes. Then I burnished the seam with the side of a pen and let it dry. The seam isn't invisible but It is close enough to not show up in pictures much at all, the edge-on shot is looking right at it. It is down tight enough to resist picking at it with my fingernail, seems to be a very durable seam.
The result looks much like the original in profile except for the added riser, the added thickness and gentling of the corners is subtle but provides a much more confidence-inspiring grip to me, improving the feel of the sword to an impressive degree considering the effort. Total time was about 5 hours including the staring.
I didn't take any before pics unfortunately...





