Chiro, and the rest of the gang, here's something I might actually be able to help out with. I work for an engineering thermoplastics material supplier, and I have in stock some test plaques that we use for flammability certification tests. The plaques are 4" X 14" X 0.040" (102mm X 356mm X 1mm). There are two different materials I have that accept epoxies pretty well.
The plaques below are unfilled nylon 6/6 and the quantity of each that I currently have:
13 dark blue (navy)
16 black
17 dark red (burgundy)
20 dark grey (slate)
I also have a number of plaques in unfilled PBT polyester, the same dimensions listed above, in the quantities and colors below:
11 bordeaux red (dark burgundy)
13 black
Assuming the average handle dimensions of 5-6" by approx 1 1/2-2" tall, you could probably get enough material for two knives out of each plaque.
If anyone is interested in trying these materials out or if you have any other questions about these materials, just drop me a line with your address and I can send a few plaques out to you (specify color, please). We don't often test these materials, so the stock I have is currently it, and I'm not sure when we'll be molding again.
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Don LeHue
The pen is mightier than the sword...outside of arm's reach. Modify radius accordingly for rifle.