Lynn, I own a few skeletal handles, typically on neck knives. My ROb Simonich Cetan Tanto kit knife had a skeletal handle, too, but I finished it with Micarta scales and drilled/filed the holes out through the scales.
I think skeletal handles are a nice idea. I offered an idea on the Spyderco forum a while back, so I'll bring it up here again...I think an AWESOME idea would be to offer s skeletal handle with holes for screws to fix scales to the handle as an additional option. You could have pre-made scales drilled, shaped, and ready to be sold as options. I think you work exclusively in Micarta, so woods would be out of the question from you as a source, but there are half a dozen commonly available Micartas, so a person could mix and match as they like. This would only work, however, if there were tight tolerance controls on the handle profiles and placement of the screws. This would probably require laser cutting of the the blade blanks and screw holes and that may be a loss of control over production that you feel is crucial. It is do-able, though, but probably more so on a production level rather than a handmade one.
As far as cost goes, let's see...
$150 knife to begin with. Subtract materials for the handles...pins, epoxy, and Micarta scales, plus sandpaper if you use it, and you're probably knocking about $10 off the cost right there. Subtract the time, which is most important, to finishing the scales, and that is a significant savings. I think it would be fair to knock $50-$70 off the final price because so much work goes into fitting and finishing handle materials. Especially if you plan to bead blast the things...you grind, heat treat, clean up, blast, and sell! If you do go with the replaceable scale idea, I would think $30-$40 per set of scales would be appropriate, with the upper end being nicer materials with a polished finish, for example.
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