Shaping Scales for Folders

[Rob Ashley]

Hey all, I've got some micarta that I'm going to be crafting into scales for my Spyderco Chicago, possibly my Mini-Griptilian and/or Delica and I've got a few questions for the pros:

1. How do you shape your scales without damaging the screws or liners with the sander?
2. What type of sander/grinder do you use?
3. Any advice?

I'm just doing it in my garage on my workbench (with a big fan and a respirator). I've got a Dremel with some attachments and the "drill press" stand for it, and I'm going to most likely be buying/borrowing a 1x30 belt sander from Harbor Freight. Anything else I need get?

 

[kuraki]

1. How do you shape your scales without damaging the screws or liners with the sander?Screws should be counter sunk/bored below the finished surface prior to shaping but I also use mule screws that will be replaced on final assembly.
2. What type of sander/grinder do you use? 2x72, hand sanding and a buffer
3. Any advice? Buy extra screws. Work with hand tools when you get close to finished dimensions, especially since your sander cannot be slowed down.

 

[Rob Ashley]

That's great advice about the screws, and you're solidifying my conviction that I need a 1x30 belt sander. Thanks for the tips.

 

[Drew Riley]

1: Like Kuraki said, sacrificial screws. Alternatively, you can use double stick tape or a drop or two of super glue to hold each scale to a "handle", and shape the scales individually that way. Small pins can even be used for additional support if needed. When done, drop everything in some acetone, or heat with a heat gun, remove, and clean.

2. 2x72 grinder, buffer, disc sander, hand sanding, etc...

3. Buy extra material and just practice. Not all materials cut and shape the same. If rounding an edge/corner, sometimes it helps to chamfer a flat first, and then start rounding.