First, the project started with a hunt for the right wood, using the original pistol handle as a guide in finding a piece of appropriate size. After transferring the basic dimensions onto the wood, make a rough cut with a bandsaw. Afterwards, re-sawed the wood using a bandsaw to create a new handle blank.
The next step involves routing out the inside of the handle halves to slide in the metal tang of the pistol. Transfer the unique shape of the metal tang onto the insides of the wooden halves. Set up a simple jig to hold the pieces and free route the inside to create a pocket for the tang.
Check the fit after each pass with the router. Err on the side of too tight versus too loose. Once there is a good tight fit, clamp the two halves and test again. Make adjustments and prepare for gluing. Aligned the two pieces, use a generous amount of wood glue, then clamp tight and leave overnight to dry completely.
Now’s the fun part, check the fit again, if you erred on the side of too tight, file out the slot until the perfect fit is achieved.
Once the fit is perfect it is time to shape the wood into something smooth, elegant and comfortable. Make rough sanding with a table sander or angle grinder then use an orbiting sander for the final shaping. Keep testing the size and shape of the new handle until the block of wood in transformed into a suitable pistol handle. Use the original handle as a guide and ensure the final handle is comfortable in either hand. Keeping the pistol handle ambidextrous is key. When the final shaping has taken place move onto the final touches.