Making your own scale liners

[MolokaiRider]

I recently stripped a KaBar Turok, and after reattaching the scales the forward screw is sitting proud. I started to sand down the screw, but thought I’d rather try to cut a spacer/liner instead.

My questions are...
A source to purchase G10 liners somewhere around .039 thick or less.
Are there alternatives to G10?
Will disposable plastic cutting boards work in a pinch? (Cheesy I know but they are inexpensive)
Recommended cutting tool to keep edges as clean as possible. Is an Exacto knife with repeated scoring enough?
Should I heat the material first before and during cutting?
Should I drill the holes smaller than screws, heat the holes, then press fit the screws to keep tolerances tight?
Will it be nessesary to bond the scales and liners with epoxy or glue?

Thanks in advance for your help and patience with my lack of experience.