1: Honestly I like the flat scales on the mini grip, but not the full size grip. The full size grip has particular issues, pivot lenght, liner screw lengths, that make it difficult to go thin enough to really create a different feel in the pocket. In the hand, it doesn't really feel thinner either because while the scales over all are thinner, they're actually thicker around the edges so you end up with a knife that doesn't feel much different in the hand either. Another thing I don't like is because the liner screws are long I can't counterbore the hole deep enough that the liner screws don't protrude very slightly. It's a little thing but it bothers me. What I really need to do is come up with a thin contour version that would be the same over thickness as my flat sets but taper slightly toward the edges, this would be the ideal solution for me and my tastes, basically just a thinner gritpilian, but it wouldn't help you and the aesthetic you're going for with the flat sides scales. The reason I never did the thin contour I wanted in the beginning was I figured everyone was buying the grip for a reason so I better not change the size and shape. Apparently that's what people want or they wouldn't buy it in the first place. I always wanted to come out with a thinner version but once I started making them I never found the time to redesign, now that I'm full time with the knife stuff, a thin contour version of the large grip is definitely on the list of things to program this year.
2: You will not find any large grips in blue twill because they only sell blue twill in 1/8 thicknesses and the large grip requires 1/4 material. Even with a liner layer underneath I can't make it work with the large grip, unless you went with the flat sided version. Unfortunately the blue twill has become ridiculously expensive as my usual vender stopped carrying it, forcing me to go elsewhere, and the prices there are crazy high... so that's a bit of a concern if that's something you're interested in.
3: I can do it... I'm willing to give it another try, I have some ideas or making it a little easier.
4: I can probably come up with something similar. it just might have to be back a little farther more like the 940, I have concerns that the chamfer might cut into the omega spring pockets if it's too far forward. I just have have to look at the depths and angles and figure out how deep I can go and where.
5: Unfotunately my spools are stainless so there's no real color options, stainless silver, black coated, I can also do copper, bronze or antique bronze for a little extra money, or a solid G10 or micarta spacer.
Send me an email if you're interested in talking more options or ordering something:
Ryan_M_Roberts@hotmail.com