Scale Counterbore is too large, can I epoxy in sanding dust?

[SugarSkulls]

This is my first time working with micarta & I didn't properly chuck my bit on one of my counterbores & it wallowed out the hole slightly (see the photo below, the middle hole is too large while the others offer an interference fit). I'm wondering if I can fill the gap with epoxy that has the sanding dust mixed in with it? Anyone ever try this & get good results?

Also, I'm wondering how you do your counterbores if you use corby, Loveless, or similar fasteners. The process I recently used for this one:

1. I temporarily glued up my blade to a scale, drill the thru holes
3. then knocked the scale off the blade & glued the other scale to it
5. drilled the other thru holes thru 2nd scale
7. I then used the thru hole drill bit to clamp down the scales so it passes thru the holes when clamped so the counterbore will be concentric.
9. I then chuck up the larger bit for the cbore & drill to my desired depth repeating this 5 more times

It is a LOT of chucking & unchucking, doing it this way which is a process I would love to optimize.

I see that one of the knifemaker suppliers has a stepped bit that does both holes at the same time, but they are quite pricey at $70 per bit which I feel is VERY expensive for a consumable item like a drill bit. I would love a more efficient, but price friendly method if possible. I'm wondering if I can just grind down a regular bit while it spins in my drill press with an old wetrock to make my own stepped bit? Any insight would be greatly appreciated.

https://flic.kr/p/rrpMbU

 

[MadBug]

DIY step bit https://www.youtube.com/watch?v=84j2pH-ep6k

If you try to fill it with glue & dust that is exactly what it will look like you did. Make the other holes the same and it might look like you meant it. . . maybe. Drill them all out and sleeve the holes with something else, then re-drill leaving a tasteful ring of around the bolts and it'll look like you are an artist.

 

[SugarSkulls]

I don't know how I missed that video, I've watched several of Walter Sorrells other vids. He crafts some really nice stuff! Thanks for the link. I had not thought to do some sort of an insert. It would look strange having a lanyard hole there...but I could just use tube to pin it in all 3 spots to save the scales but I think that would detract from my intent to use corbys for a firm mechanical hold for the micarta. Maybe I can find a neat coin shaped shield or something to inlay into the material. I think I'll just suck it up as a learning cost & make another scale. I just hate to waste materials and try not to.