First folder, please advise

Thanks, sBuzek. I'll check that book out.

Just to update, I've answered question 1. 4-40s are too coarse threaded to get a good grip with so little room. I found some nice 2.5mm x .5 stainless screws and brass standoffs in my junk screw tray that work perfectly. The heads are t-9 and are exactly 3/16" diameter so they recess perfectly with no wobble!

Now, to ream out the pivot to 1/4" and cut the lock. That should be easy(yeah, right!) I will still make new scales, but since I've come this far on these with all the extra holes I may as well get the practice cutting the lock, also.
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It's not a book but DVD.Lots of good info in it.It's what got me started in folders.
Stan
 
Using the diamond bit set from HF, I was able to grind out the hardened blade to 1/4" and it turned out great. Used up about 50% of the grit on the bit, so I am ordering some carbide burrs to see if the might work in the future.

Also cut the long slot. I used the dremel cutoff wheel in the drill press and cross slide vise. It worked great. Just waiting to get the 1/4" pivot before I cut the short cut on the lock.

More accurate cross slide vise and drill press are definitely on my list.
 
Give Reese Weiland a call. I've never met him in person, but he has given me more info than I can process.
 
I need to take a pic of that jig so you can see. I have alignment pins in the corners, screws to bolt the top to the bottom, and I engraved the bit sizes next to the individual holes.
 
Currently working on a jig for the holes. Would really love to find someone local with a CNC for it.

Patrick: The diamond bit worked but was disappointing. However, a carbide burr works GREAT! Perfectly round compared to the drill bit hole! Now, I drill the pilot a bit smaller and finish out with the carbide burr.
 
After a good hours work, it opens/closes nicely. Still need to make the second scale for the lock side and get proper fitting washers. After that, just build the final scales using these as a template. Did you know you can spot weld Ti with a normal spot welder?

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If anyone's interested, here's the latest pic of the knife. I have replaced both liners with taller ones, giving more room for the tip of the blade and more distance from the spacer to the edge. I remembered to leave material for the lock tab(not certain of the term here.) Fitted with a nearly exact .250" pivot and holes in the liners give a rather nice fit and smooth opening blade. The pivot is press fitted in behind the scales and requires some force to separate. It has a very nice click when it locks open and the lock lines up almost perfectly with the blade.

The recess on the scales has been a project. The scale is 1/16" thick underneath the screw and the screw head is 1/32" thick giving me a 3/32" liner and 1/16" scale. The wood is unstabilized bocote. It seems to hold up very well, no splintering and very solid.

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