Sorry everyone I was busy all weekend. I'm new to posting on forums and I'm not sure how to quote each question, so I will just answer each one. First off I do not own a drill press or a lathe or any special tools. I made these scales in my back yard and garage using a Dremel 300, a set of files and sand paper.
First I cut the scales out by tracing the liners and gradually sanding with a sanding disc until I obtained the general shape. I then clamped the liner to the new scale and hand drilled each hole. I then used an engraving bit attached to the flex shaft attachment to do the hex pivot screw. After that I put the knife together, without the blade, hand filed and sanded all the edges to my liking. I then took the knife apart, washed everything and sprayed the scales with WD-40. Washed the scales again, put everything back together and this was the end result.
The screw holes are really hard to line up and it took me some time to get everything to fit together. I worked outside with googles and a respirator. This stuff is no joke! My face broke out pretty bad where my skin was exposed so if you attempt anything with G10 make sure you are safe about it.
I'm not going to start making a ton of these because I just don't have the time but I am curious what you guys would pay for a set of these...??