Just wrapped up a project last night. CCK small rehandle and saya.
The handle is a complicated one. The handle is over height octagonal made of Brazilian ironwood with an ebony wood ferrule. The ironwood stock I had was two ~1/2 boards so I had to rip the board, glue it up to double the height then recut it to size. Overall I am really happy with the final product.
The saya is cherry wood (I think
). I purchased one boards that was over length then nibbled one piece to a thinner thickness on the table saw. The nibbling left a much rougher finish than I had hoped so one side looks cratered like no man's land. I used a router to hollow out the thicker side then sanded it to final thickness. The fit is loose though in some part that was unavoidable. The cleaver is taller at the toe than the heel so the opening had to be taller than the height at the heel. I did not want to buy a dowel making jig or pay a premium for pre-made dowles so the pin is a beveled chopstick (stole the idea from someone here
Get in your hole: