Brian,
The lock bar is cut using a Dremel type cut off wheel. I use thin ones because I don't like it when there are wide gaps. I use 1/32" for the long horizontal cut and 1/64" for the lock face. The scale is mounted on a homemade wooden sort of a vice and just slide back and forth until you've made the cut. I can send you a picture of my setup if you like. I think it looks real clean when done right and I'm real picky about clean work. Here's a picture of the first framelock I made where you can see it. PM me if you have any questions and we'll talk.
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