My experience has been that the .010 washers are too thin and .020 too thick , for my liner locks. I use .015 phosphor bronze. I install the 1/16 detent balls by placing a .010 washer over the hole on the inside of the liner, and set the depth buy simply pressing it in with a punch and hammer. I still remove a small amount of material from the scale side of the leaf.
I have read over your notes on your pattern and your being a bit unsure of if you should go ahead as it is or not. Here are some points for you to consider. I believe you have come up with a great pattern ! But. Why not just extend the frontend of the scales to get the end of the blade to be inside? And most important why not make a hard pattern out of some stiff cardboard, thin G10, Formica, plastic, thin tin or brass shim stock even and drill the holes where the stop pin in be , move the blade open and closed by simply placing the end of the drill bit in the pivot hole that made that hole and actually find out if the clearances are there where needed. Even after that I make the one liner to actual size with the pivot hole drilled and reamed and now try the hard pattern of the blade on this. Do not use your hard pattern to make the second liner but use the first one. The pivot hole in the second one should be drilled and reamed in the piece or rectangle you will be using. This will now allow you to place a pivot pin through and give you the correct alignment for drilling the rest of the holes needed, by clamping and adding pins, drills, in the holes as you go. Some use CA glue. Not me.
Frank
