Hmmm . . . . Making a set of fancy wood scales for my own use is one of my "things to do," but I doubt if I could do it efficiently enough to sell a set and pay for my time.
I might try using the G10 scales as templates to drill and countersink the hardwood, and then bolt the two together and, with a 1x42 belt sander and sanding drums on the drill press, remove wood along the sides until it
just barely meets the G10, doing the last bit of wood removal with 220 grit so I don't make big mistakes fast, and then do the finish sanding by hand.
Shaping the surface would be tricky if I wanted to use the factory kydex sheath. I'd probably end up going to my leather maven for a custom sheath when I got done.
If you want a flush fit, you'll be removeing metal around the entire edge of the tang, since that edge is slightly beveled. The screw holes and cut-out in the tang can be used to do a pins and epoxy assembly, discarding the bolts. Of course, epoxy doesn't stick well to tefflon, so you would also want to sand that away, and, while you're at it, give the knife a hand-rubbed finish.
That's a few hours' work.
------------------
- JKM
www.chaicutlery.com
AKTI Member # SA00001