This evening I tossed a piece of scrap teak in the thickness planer and spotted some of those "quarter sawn fleks" of light thrown off. This piece came off of an old gas BBQ that sat outside for years. You remember the ones with the little side tables made of wood?
I ripped the piece and selected two sections for the scales. My initial rip on the bandsaw didn't go too well and I ended up finishing the rip in the tablesaw with a thin kerf blade.
In order to align the scales and keep them in place for shaping, I am going to use dowel that I can drill out afterwards. The trick was to carefully align the front angles as precisely as possible, while only being able to drill one scale at a time. Patience! I trimmed some short pieces of poplar dowel and tapped them in to hold everything together.
Once the tang was sandwiched, I went to work on the belt and disc sander to bring the scales closer to the shape of the metal.
Belt sander to chow down on the pins.
For the curves I used a small drill type sanding drum in the drill press. 1" drum with 80 grit.
A note on the handle shape. I wanted the front of the handle to be similar to the ricasso line, but not exactly parallel. I was looking at the lines on my car the other day and thought of a handle shape.
Next I'll shape the handle with a rasp and sanding papers.