Success! The new process takes half the time, conserves materials, and appears to produce a stronger handle. I'm about to put the finishing touches on a kukri made with this process.
I think part of the problem is that the wood I've been using hasn't been precision milled. That leads to warps and bends that the gluing process can't sort out.
Until I get skilled at this new process I'll sell the knives at a discount. They're still just as strong but the slight imperfections in the handle will bug me and I don't want to sell them at full price until they are gone.
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