Dodgeem33,
From what I see in the pics, the two sets of handles you have are show slight modifications we have made in the ergonomics of the handles (not one being the original style handle). The handle material thickness that we receive may vary slightly from lot to lot but generally we seek to maintain .250" nominal thickness, in rare instances we have received material that was under size by .008" (the approximate thickness of 2 human hairs). The coated knife will be thicker than the satin because of the coating itself, coupled with the radius on the coated knife being slightly smaller makes the overall assembled handle thickness looks more than what it actually is. One of your post says the overall thickness is 1/4" different from one knife to the other - if that is actually the case you may have one of the rare sets of handles that were custom made from 5/16" or 3/8" material, the pics don't really look like that is the case. If you use a pair of verniers or micrometers to measure the overall thickness between the to blades you would probably see .025" difference, if more one set is most likely a custom set.
Jay
John 14:6