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Teddy,
I actually did that on the Kukri that I made for the guards, and I did it after HT and tempering.
My trick is to have a massive heat sink on the blade so you don't distemper it, a wet rag between a couple of 1/2 steel plates does the trick for me. If I'm going to fix a guard to a knife I'm going to either solder the guard, pins, or both to the blade, I don't want it wandering off on me.
Also, just to be contrary, you can fill in smaller gaps (1/8" at the MOST, and then it will look like butt) with solder.
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