I'm thinking of putting a different pommel onto an ATrim sword. The existing pommel is a large wheel and I'm looking to add a shorter scent stopper. The problem is I need to cut off a portion of the threaded tang. I'm pretty sure this will mean work on the altered threaded portion to ensure the locking nut is able to screw on. Any advice on how to do this? Take it to a machine shop maybe or try it myself?

I my experience, cutting a regular bolt to size with a saw damages the tread, which one then have to straighten out to fit a nut on.

It can be done by grinding the tip slightly rounded after cutting, but one nice trick is to leave the nut on and use it to straighten out the tread by unscrewing it.

So put on the nut, cut above it, grind the tip of the tread, and screw off the nut.

You can do it with a rough sharpening stone, the lack of space above the nut will ensure that the rounding of the bolt/tang is only slight. ;)

Personally, I would re-do the grip before messing with the steel. but if you are shortening by just 2, or 3 mm or so then the nut trick and grind the end rather than cutting it. if much more than that I would make a new longer grip. tr

I've used a tap and die set on a tang before. Worked really well. I didn't shorten the handle just had to make a repair to a stripped tang.

Hello,
Why not simply take off what you don't want, and then put on what you do. After it is all on tighten down the nut...and cut of the excess. Then give it a light peen.
Cheers

Sometimes the "screw on the nut then cut off the excess and unscrew the nut" method doesn't work. If the nut is softer than the tang material, you'll screw up the nut before the tang gets cleaned off. Better to use a die, screw it onto the tang, cut off the excess, then unscrew/rethread the die off the tang.

Better yet is to hot peen, then sandwich the new grip onto the tang.