i usually clean out the burr from grinding by running a large wire or a drill bit through the hole, then countersink or use a really big drill bit to countersink...
I use a reloading case de-burring tool, on stag. On the micarta grips, the polishing takes the burr off. I don't use the thong hole tubing sold by the suppliers. It is thick and soft. That is why it makes such a nasty burr. I have been using Easton Archdery Arrow shafts. It is hardened 7075 Alu. with a T-6 heat treat. VERY Hard stuff! You can throw a piece onto a concrete floor and it will ring like tempered steel!. Last for ever! And the inside polishes like a mirror!
But the best part is that you can get it in a very wide variety of sizes. A little pricey though.
Hello Michael, you could pick up scrap pieces of aluminum arrow shafts from an archery shooting range or archery shop for free, I would think. Although some people may be saving the aluminum for recycling sale.
I use aluminum arrow shafts as well, pick them up at the gunshow's, pawn shops ect, buy in bulk about once a year or so....picked up a few off ebay. Use a 6 blade countersink in the mill to cut the edges and polish that up with the foredom with a jewelers attachment to polish the port and inside the tube to a mirror finish.
The difference between a $200 knife and a $300 knife is $5.
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