I thought a few of you would be interested to see how I made 7 identical (well, close anyway..) sets of scales.
first step was to draw my scale shape on paper, and cut it out, and then outline the paper onto my material.
Next up, I cut them out using my band saw:
After I rough cut them, they looked like this:
Next step was to double-sided tape them all together.
This allowed me to get a matching profile on all 7 sets.
After that, I seperated them out in pairs.
And then proceeded to thin them out to around .22" for both scales. (This is before any shaping is done, so, the end product was closer to .10" each)
After that, I drilled the holes!
Then I proceeded to shape the scales. Initially I used an 80 grit belt, and eventually moved all the way up to 400, then I went to hand sanding them. Here they are after 600 grit paper.
I made some black horn wedges, and separated out each set of scales, ensuring to mark which went with which so as to ensure perfect matches (since there are likely minute differences).
After that, I pinned the wedge ends, and sanded down the excess horn. then I gave everything a buff!
and thats it!