Jarod,
I've thought of doing this before .It wouldn't run a whole lot more than the cost of a set of high end mammoth scales, and would be less than narwhal.
This is the procedure I wrote up and filed away for a rainy day:
(parenthetical notes added to make the outline clearer to others)
Materials: $200 new bills, clear resin, cardboard.
(Use a clear cast resin, like System Three Clear Coat.)
Make a box that exactly fits the bills from wood with a top that fits in it like a piston.Make the top and bottom out of 2" thick wood, the sides from 1".Drill (lots of )1/4" holes in the box sides (until it looks like swiss cheese, but leave the top and bottom solid).
Put three pieces of poster board in the bottom.
Coat each bill with resin and set in the box.
Place three more pieces of poster board at the $100 point ( no resin).
Place next $100
Add three cardboard on top (when all the bills are in the box).
Put on the top piston.
Put assembly in lg. zip lok bag (to catch all the resin drips).
Place in a clamp/press and tighten to expel the extra resin (it will leak out the holes).
Let cure (for a couple of days).
(Put the box on the) Band saw (and cut the)sides away, (then) the top and bottom.
Grind down until the poster board is just barely left on the top and bottom (and) split the scales (with a sharp knife )in the middle. Grind insides flat (and you have a set of $200 scales).
This has me thinking of this project again. Maybe I'll make up some damascus with $$$$$$$$ all through it? That would be cool. I wonder if Donald Trump wants a fancy letter opener?
The sad thing is the amount of extra that will be cut/ground away . Maybe with careful trimming some of it could be saved (like the $1 corners) and used as an inlay on another knife or the presentation box for this knife)
Just thought of a better idea while typing.Carefully cut the surplus away fron the tang after applying the scales. Use those fitted cuts as liner pieces for the presentation box ,so the knife fits back in-between them,to show what they came out of. Now that would make the whole package look impressive.
I like the idea of using foreign currency. I have a friend who might be able to get a couple of bundles of new Iraqi of Afghan bills. That would make the learning curve a lot cheaper.
I could send an email to a Nigerian bank and say.
" Helo, I am wealthy amercan who has $100,000,000 that wish to share good fortune to you. Please send 1" of new Nigerian bills to me and I wil send payment by creidt card. Thank you much."
Stacy