The process of compiling, compressing, shaping and coloring the leather washers used to create the traditional KA-BAR knife handles is best left to the experts. Still, if you've got the proper machinery and would like to give it a shot, we do offer a handle kit which includes washers, spacers and a butt cap. Please contact KA-BAR Customer Service at 800-282-0130 to place an order.
If you want to duplicate the old USMC Ka-Bar look, they sell stacked leather washers at many knifemaking outlets, they shouldn't be very hard to find. The original pommels are just steel caps with a pin that goes in and locks the pommel in place, the washers need to be compressed somehow and the pommel installed for a proper fit. Once the washers are on you can tape off the guard and pommel, use a coarse sanding belt to shape the leather, and finish off with a wax, not oil.
From the KA-BAR Knives, INC. site:
From a knife site:
No disrespect meant to the resident knife makers, just trying answer a question...