A method of repairing a gas turbine knife edge seal assembly in which assembly is included a used honeycomb ring seal and a knife edge. The method includes removing the used honeycomb ring seal, removing material from the knife edge to a first knife edge radial height, installing a replacement honeycomb ring seal with a stock radial thickness, and removing material from the replacement honeycomb ring seal to a finished radial thickness for sealable engagement with the knife edge. The finished radial thickness of the replacement honeycomb ring seal establishes a first radial gap between an inner annular surface of the replacement honeycomb ring seal and the knife edge before the knife edge seal assembly begins rotating in the gas turbine.