dammit Ebbtide, I thought you ordered cocobolo!
TBG, I used 1/8" thick ivory Micarta. Carefully peel out the rubber inserts and use them as a pattern. Cut them out with a scroll saw to the rough shape then use files to shape them so they pop into the milled out recess nice and tight. You may be tempted to use a Dremel here but I would stick with the files as they remove a lot less material and will give you a better fit.
Once you have them all shaped chamfer the edges with a file and sand them, I usually start at 100 grit and go to 250 grit - then finish off with a green scotch brite.
Pop the Micarta back into the handle and use the proper drill bit for your tap to drill through the Micarta and the aluminum scale. Pop out the insert and tap the hole. Now bore out the hole in the insert to fit your button head screw and counter sink it. Touch up the Micarta with your green Scotch brite and screw them in place.
Now on the back side of the scale use a dremel or bench grinder to grind the excess length off of the screws so they're flush.
I got the Micarta from a combination of Texas Knife Makers Supply and Koval's - I have a ton of it so I'm not sure which place that particular piece came from.
Also note, 1/8" stock was a good fit for the SOCOM but with the CQD I had to this the Micarta down to a little less than 3/16".
Good luck!!
PS - I would only try using Micarta if you're not familiar with this stuff. G-10 and Carbon Fiber are
much harder to work with. All of them are bad to inhale so wear a respirator too
