bolster handle mating gap help!

That's cool man, a labor of love. Not to mention I am green with envy. And when I saw your process, I thought of myself and how I tend to do things. It's hard to have blind faith that things will turn out like you expect them to lol.
 
Some times you have to weigh your time and expense of trying to repair a flaw. I would start with new scales and apply them one side at a time like Sam suggested. I know stabilized D.I. is not cheap but the old scales could still be used for spacers or bolsters. I was trying to salvage a handle once and after too many attempts realized I was polishing a turd and and there was nothing left to salvage. Lesson learned.
 
That's cool man, a labor of love. Not to mention I am green with envy. And when I saw your process, I thought of myself and how I tend to do things. It's hard to have blind faith that things will turn out like you expect them to lol.

That's the truth, I get so nervous when I lay scales onto the 2x72, it rips material off so fast I get nervous, that's why I prefer to do it by hand.
 
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