Good morning Jens, 
 
I think if a hilt has koftgari in good condition and a worn blade, there is a strong likelihood of the blade being rehilted....but for a blade with a munitions grade hilt it would be rather hard to say. 
 
Apart from the old tulwar I have that had been attacked with an angle-grinder, I have never seen a tulwar with severe grind-marks to the edge.  Could this mean that a worn blade was sharpened many many times, by removing the least possible amount of metal, and not just a few times by someone removing a lot of 'beef' all at once? 
 I would think so, as these were often heirlooms as well as weapons, and I would imagine that they were preserved as well as possible and not sharpened away needlessly. 
 
I have a rather old tulwar, with the blade worn down by maybe 25%, but the hilt in this case has most of the koftgari worn away, so the two parts may be original to each other. 
I have often wondered when a tulwar blade was considered to be past being useful. 
The worn one mentioned above, has the sometimes seen rather thick spine, but the blade is now  rather narrow.  
I wonder; It has been kept sharp, so was it considered a viable sword to take to a fight?......a secondry weapon?  
 
Re. hilt size; 
Most are tight for westerners as we know, but the more one handles them, the better they feel!   (Just my opinion!....maybe my hand shrunk) 
I know that in parts of India, people have very small hands compared to Europeans. 
Sometimes there is talk of the first finger being placed over the cross, but I think not, and don't want to open that discussion again. 
When looking at some katars a while ago, I found I could not fit my hand into any of them, ....and with a katar there is nowhere to place the 'extra' fingers!.....so must deduct that the tulwar hilts fit the inended users well enough. I 
I will try and take a picture of my worn-away blade, and show here. 
 
Best wishes,  
 
Richard.
		 
		
		
		
		
		
		
		
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