I'm listening to all ideas. By the way I think I had a bout of dyslexia when I said this was a type 35. I guess I meant model 1935 and type 95. I had a good conversation with Robert Benson from Honolulu, Hawaii who does restoration on Japanese swords. He had told me that once apart He has used thin wood slats/shims made from cigar box wood. I figure it will also need a new leather washer. I plan to make one using the old one as a template and utilize some thick steer hide like used to make bridals for horses. That should last another 80 years. Robert referred me to the book Swords of Imperial Japan 1868-1945 Cyclopedia Edition by Jim Dawson, page 191 where it is supposed to display this exact sword disassembled. Anyway this thread has some excellent pictures of the wood insert and that's a pretty damn good start. I'm just a little wary of taking off the sarute and don't want to bend it too much that it breaks either coming off or pressing it back on. As far as that double slotted screw/bolt at the hilt, I plan using two flat tip screw drivers with the exact thickness and length of the slots. You guys have any other recommendations (except leave well enough alone)? As far as pictures of my Copper Handle NCO Shin Gunto, I'm sending a link of where my sword originally came from before I acquired it from it's latest owner who is an NMB member, Tom Clancy of Ireland. http://www.antique-swords.eu/copper-hilted-Japanese-ncos-shin-gunto-katana.html