Recommendation? Trying to mill inset liners. Need advice

R

Rob Ashley

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May 31, 2018
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I've got two micarta blanks that I want to create some scales from. The problem I'm running into is that the knives I want to create scales for all have inset liners. I've toyed with the idea of just letting them show, but decided against it. So, the question is, what's the best way to mill out the recess?

I've got a 1x30 belt sander and a Dremel to help me remove some of the outside of the scale, but I don't trust my hands to be steady enough to free-hand the recess with the Dremel. I've got a small router that will probably provide the solution, I just don't know how to set it up to work on something this small. If I buy anything else, my wife will stab me with one of knives. Any info to help get the job done would be great.
 
A router is fine with a proper end mill, but you need to support the base appropriately. If the micarta is of a standard thickness (say 1/4") just use 1/4 ply scraps on either side of the scale to support the base.

You could make a simple router plane if you want some very precise control, but micarta is a bit of a bitch to work with hand tools. You need to use minimal cut depth. The router is how I would do it, with both the scales and the support scraps all secured to your work surface.
 
joedhiggins said:
You need to use minimal cut depth. The router is how I would do it, with both the scales and the support scraps all secured to your work surface.
Click to expand...

Getting the scales secured and in place is going to be difficult. I may end up cutting a rectangle into of a piece of plywood and setting the scale in that to work on. Thanks for the tip.
 
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