Full tang scales not lining up

[Skiller1nc]

This method 100% guarantees all pins will align when reassembled.
Here is how to avoid the issue:
Glue or clamp one scale to the tang.
Drill the holes from the tang side, placing pins through the holes as you go.
Remove the pins and clamp/glue the other scale on.
Drilling from the already drilled side, drill through the second scale, placing the pins in the holes as you drill.

Other tips -
Drill the tang holes 15-25% oversize. This prevents binding when inserting the pins.
Use sharp and short drill bits.
The pins should slip through smoothly, not tight, not loose. Select the right size bit and use a reamer if necessary.

I know I should have done this, I've used this method before, I just know plenty of people who do it the other way and it works fine, figured I could save some time that way

 

[Horsewright]

I know I should have done this, I've used this method before, I just know plenty of people who do it the other way and it works fine, figured I could save some time that way

Pretty much what I do and I do also have a fondness for the shorter screw machine length bits. They do make a difference.

 

[Skiller1nc]

Here are some pictures

 

[Hubert S.]

I agree with all the tips above, the stubby bits in particular are very helpful. Another source of problems could be fixturing or how you hold the work piece. If you are slightly off in your initial alignment, the drill either deflects, or it pulls the work into alignment when you (gently) bring the drill down. The drill can only align your work if your work piece can move freely, so don't clamp it or hold it down with a death grip when you start drilling. Also, don't use a drill press vise to hold your work, a small bit won't be able to move that and will deflect and drill the hole at an angle instead. Not sure if that's the issue, but I thought I'd mention it just in case.

 

[FredyCro]

Here are some pictures

That looks like sth was out of the alignment. Is your drill press table straight when clamped down? How much does it give when pressing on it?

I second the short drill bits and also putting the table as near as possible to the piece.

Sorry if you know all of this already.

Maybe to save the scales you drilled (the ones that are only a little bit out of alignment) you drill the tang holes one size up with a carbide bit or a masonry bit.

 

[Skiller1nc]

Okay, the problem has been resolved. I drilled the micarta holes up to 2.5mm (.098") for the .094 pins. I drilled the tang holes from .094" to 0.125".
1. Finding number or metric drill bits in person is impossible, I had to buy a metric tap and die set that included bits to get a 2.5mm bit.
2.Some masonry bits work but not all, home depot brand wouldn't drill 61rc D2, bosch made it 2 holes and lost the carbide, Irwin made it 28 holes, and still seems like it has some life.
3. These pins I think are 416 stainless but bend and move like maybe nickel silver, idk but they are so bendy and weak and are a pain in the butt

 

[Taz]

I am usually able to find wire drill bits at local hardware stores, but they are near the taps, not the regular drill bits, so they are often harder to find in the store itself.