Hey, JLo, thanks for digging up those pix.
RX is totally right about shaping the FRONTS of the scales before they are affixed to the blade. However, since I don't know what the final contours will be before gluing, I reserve breaking those forward edges until I'm about to do the finish sanding, which is all by hand.
Personally, I don't do any to-tang shaping with the scales off the knife (except rough bandsaw cuts). I find it to be too much messing around with parts back and forth. I use a slack belt on my 1x42 to break those edges usually, but it could also be done during the hand-sanding step with the blade chucked into the vise. As soon as the glue is set, I tape up the entire blade anyway to avoid minor bumps - of course major bumps are always a risk...
As for BRKT (and I'm a big fan of the Fox River family, btw), I suspect they avoid very fine motor control operations like this because it's slow. And it's risky if done fast. They have optimized for higher production volumes, and that's a trade-off. As far as other custom makers are concerned, I don't know why we see as many sharp-edged handles as we do. They look nice in photographs sometimes because of the lighting contrasts, but my own experience suggests they're not as fun to actually *use*.
re: guards on full-tang knives
It can be done with a slotted guard. Seems like a lot of work - I'm not a huge fan of big guards on non-fighters. Many of the BRKTs, and indeed my Hiker model that JLo has pictured, do not have guards at all, even integral to the blade/handle. This arrangement requires a bit of care. On mine, you would find that the back 'tip' of the edge has a 45d bevel to reduce the possibility of cutting yourself accidentally. You can still use the entire edge. Also, too much taper to the front of the scales will cause the knife to slip deeper into your hand, which is risky with a guardless knife.
Cheers,
-D