Hi All --
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