Mismatched Scales, Limited Tools, Need a Little Hivemind Ingenuity.

[apatientwolf]

Hey everybody,

So I bought some inexpensive Black Walnut scales on Amazon (for the first and probably last time), and they showed up mismatched as all hell. I decided to go for it anyway, and this is what I wound up with (more below, sorry for large pics).

Forgive the gruesome JB KwikWeld smears; it was all I had on hand. Anyway, muscled in the pins, set for 6 hours, started filing away the excess. But now, I'm wondering how the heck I should profile this handle given all the excess material. So any suggestions as to A) Inspiration photos for handle shape, and B) suggestions on how I should go about making this thing look nice, would be greatly appreciated.

Embarrassingly, I don't have a workbench here. What I do have is:

• A Belt Sander (Old and Crummy)
• An Angle Grinder
• A Dremel
• Loose Strips of Sandpaper in 100-220 Grits
• A 10-Inch Stanley Half-Round Bastard File (22-099)
• A 10-Inch Half-Round Wood Rasp (Very Rough Toothed)

I also have a small (5-Inch) Yost Vise that I could theoretically bolt into the railing on the balcony.

OK, knowledgeable knifemakers! Please give me any suggestions you've got on how to do this baby right. Thanks! Here's some more pics for reference:

 

[Drew Riley]

I would have matched the scales BEFORE putting them on, but nevertheless, you can still likely salvage them. Start with a lower grit like some 50 grit on the belt sander and hog the thicker scale down closer to the thinner. Contour as desired with the sandpaper or file, and then take everything to a final uniform finish.