Anyone Work With Zytel?

[ednemo]

I am interested in making a hand weapon for my students and have come up with some designs. It looks like Zytel would suit my needs but I am open to other options. I am really interested in making this myself. Anyone have any advice?

 

[Cougar Allen]

The advantage of Zytel is it can be injection molded for mass production at low cost. If you're going to make a limited number of something you can't tool up for that. You could grind Zytel to shape by hand, but if that's the way you're going to make something you could choose other materials without any greater labor costs -- exotic woods, G-10, Micarta....

Wood would look prettier. G-10 or Micarta would be stronger and tougher and not have that plastic look and feel.