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Hmm, Les must be snoozing. I doubt he'd know how to do it anyway.
I have never made a hollow handle survival knife, and never will. I find them to be a gadget knife only, without a lot of use. I also believe them to be rather weak. However, some people like them, and that's okay for them!
The weakness comes, in my opinion, from a short tang. The Lile tangs were just 1/4" square tangs that were rounded and threaded with the tube soldered in place. I believe Jack Crain's knives had a tang that was as wide as the inside diameter of the tube. If attached well these would be stronger than the Liles.
I think the best way to attach the tube to the blade would be to make your blade tang as wide as the tube, like Crain. Machine two blocks that form a circle the same as the inside diameter of the tube minus the thickness of the tang. Solder the plugs and tube to the tang. Lastly, drill through and pin it with at least one pin. Other than machining them from a solid bar of steel (Chris Reeve's style) I don't believe there is a stronger method.
You could probably use a good marine grade epoxy instead of the silver solder. Not that 5 minute slop, or anything in a bubble pack at the grocery store or lumber yard for that matter. Use the good stuff!
David
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