Cutting Scales, Bolsters and Liners

V

velodemon

Joined
Feb 14, 2012
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This may be a silly question but what type of saw and blade is used to get the"seamless" look and feel of bolster to scale and the ultra thin liners I sometimes see between bolsters and scales? Thank you all for your input.
 
Usually liner material is bought at the desired thickness. As far as the scales are concerned I cut them to size with a band saw and then flatten on a surface plate with sand paper. Bolsters can be ground true, or pretty close, on a disc grinder and then hand sanded on the surface plate if needed. Once everything fits together nice and flush it's all just a matter of grit progression with sanding.
 
JG Custom Metal Works said:
Usually liner material is bought at the desired thickness. As far as the scales are concerned I cut them to size with a band saw and then flatten on a surface plate with sand paper. Bolsters can be ground true, or pretty close, on a disc grinder and then hand sanded on the surface plate if needed. Once everything fits together nice and flush it's all just a matter of grit progression with sanding.
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Thank you very much!
 
No saw blade will give you a seamless finish. I mill my bolsters to I know that they are square where they meet the handle material. It is all about taking your time shaping and sanding. Metal does not sand off at the same rate as wood because the wood is softer.
 
To that end, make sure you have a hard backing when you are sanding your bolster/handles so you do not remove material faster on the handle material and get a "dip".
 
I cheat. After cutting them to approximate size, I epoxy them in place with pins in already.

After the epoxy sets, I sand them to final fit. No gaps and keep polishing to desired finish.

Larry
Tinkerer
 
Thanks for all of the input folks. I've tried a few times and just have been having trouble getting a completely flush seam. I'll try these suggestions and keep on practicing.
 
We cut all our material on a table saw. We use a disc grinder to grind the bolsters so they fit seemlessly.
 
same as Fiddleback....cut scales on a 10" table saw with an 80 tooth thin kerf ultra-fine cut carbide blade. Sand as needed on a disc sander.

It should go without saying that a slide table, fence, and push blocks are used to cut scales.
 
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We actually made a special sled for making the dangerous cuts from blocks into scales (for things like stabilized wood). It is a very dangerous cut. For sheet goods we use the fence and push sticks.
 
You might make little undercuts in the bolsters or scales where it's buried and won't show, so that you're only fitting a smaller amount of material against each other or the blade. It might also minimize glue up surprises. Also, make sure you're happy with how true the blade is where it meets your materials.
 
Stacy said the magic word, 'disc sander'. Cut them slightly over-sized, then true up the edges with the disc.
 
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