This is an awesome topic, with great posts...

I'd like to add that what is often overlooked in this kind of thing is that there are a myriad of ways things can, and have, been done, with each method having pros and cons, each method having situations that can often guide the choices of methods used... I think what is critically important throughout is that whatever method chosen is one that's done well. Skill of the craftsman, the practice involved in the method, the approach and care taken, really seem to me to be in the end the most important factors determining the quality of the end product.
Personally I've tended towards building grips off of the sword and mounting the hilt all at once, but the guard and pommels are still wedged into place, the end result is not so different from building the grip after the fittings are in place... however, it is certainly a different approach and requires that quite a few things have to be considered beforehand, with regards to how everything is going to fit together. In that case I cold-peen the tang ends, but this too, has it's own set of requirements that have to be considered to ensure things are properly seated and strong in the end product.

After meeting Peter and seeing his preferred method in person I've worked with that more as of late, and I like it too, and it has many merits, and will use it in the future.... but I'll still do it the other way as well. Mainly, they are just different methods, with different paramaters that need to be adressed to make everything "right" in the end. I found quickly the main issue is always that whatever method is used, it's just gotta be done well. Hot peen, cold-peen, threaded, nuts, grip before, grip after, it all can be done well, it all can be done not-so-well. Just like forging or grinding, just like heat-treating.

I will say though, after getting used to building grips onto the sword after the fittings were mounted, I've come to like the method since it reduces some of the real pain-in-the-butt trying and re-trying and measuring required to mount a hilt all at once. I'm not big on math... :0)

Hi Randal,
Its been a great thread,I will be revising some of my earlier opinions as a direct result,as well as having made the acquaintance of some good people along the way. I will always forge my blades however,despite the various contentuous issues around the viability of forged over ground, there is something absolutely engrossing about working a blade through the fire,and although it may be seen as Marketing i genuinely believe that the Will of the Smith manifests itself through the hot steel,and that attention is its own reward.

Dayum, sure learning a lot here! Learning a whole lot about how much I do not know.

Dayum, Happy Collecting!

Bob