I used to burn the handle onto my the hidden tang knives I made, but had several handles crack or warp from the heat.
I recently started using this technique instead of the drill, file, file some more, file yet some more, needle file, needle file, etc.
Step 1: Drill a hole whose diameter is slightly larger than the widest part of the tang.
Step 2: Fill the whole with a two part epoxy putty. You can usually buy this at Lowes or Home Depot. It comes in small tubes like this:
You break off a chunk and knead it together. It hardens in about 20 minutes. We use this stuff to repair boats in the commercial fishery. It even hardens underwater.
Step 3: Coat the tang with petroleum jelly, and slide the tang into the putty filled hole. Then remove it.
Voila. Perfect fit.
I like this stuff a lot more than using regular epoxy because you can form it and remove the tang before it sets.
Hope you guys find this useful.