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Doing Away w/ Edge on Merker Progress' Plastic Adjustment Knob

If you're tired of feeling the 'flash' on the end of your Progress handle's plastic adjustment knob, here's a way to do away with it. Flash is that bit of edge we feel on the Progress' plastic adjustment knob. I've had my Progress razors for some time, and the sharp edges have bothered me. Today I said enough: I got out my Dremel tool, put on a mildly coarse wheel, something like less abrasive steel wool, and in a radius I began to rid the first plastic knob of its 360-degree sharp edge. After making about two passes with the Dremel, one against the sharp edge and another in the opposite direction, the edge was gone and the edge of the plastic knob now has a smooth radius that feels fine when shaving. It was a simple fix and one that I likely could have done by hand with super-fine sanding material; but I thought the speed of Dremel and material I was able to use would make the perimeter of the knob more uniform--and it has done its job. The color of the plastic after the resurfacing is the same ivory color as it was, I cannot discern any discoloration from the newly exposed plastic material.

I had thought of getting a Mergress, but I don't want the added weight of a steel knob on this razor. For me, the standard Progress is heavy enough as is. The Mergress looks great and may feel fantastic, but I'm not sure that I want to get one without being able to heft it; and with razors we know that returning is often not possible. I had calibrated both my Progress razors so when each is 'locked down' the dot on the handle is on #1. I have mine set at 2.5, which means that I have the gap set at 1.5 on the razor's scale. I know these razors are not calibrated at the factory, and as a result it's difficult to find two out-of-the-box razors identically calibrated. This is really of no consequence, I simply prefer calibrating my gear when possible.

I originally posted this as response in a discussion on the Progress, but without the edits made in this posting; so if you think that you have read this before, you likely have. But thought if the flash on the Progress' adjustment knob bothered me, it likely bothered one or two other guys.
 
It was a minor annoyance only; yet one of those things where one says 'One day I'm going to...' The Progress is a fine razor, but Merkur could step up its production values, especially on the way the company injection molds and finishes such an inexpensive plastic part. Nonetheless, of all the razors I own and have owned, I go back to the Progress. For me it's a tough razor to best. And now that I'm using Persona Surgical Prep blades--it's double-edge Nirvana.
 
I have my pinky on the the side of the razor's end and could feel a ridge of plastic around the perimeter of the plastic knobs on both Progress razors. Both feel good to me after the minor modification.

Calibration: After removing the blade I locked down the head and and while holding the head stationary I moved (actually a twisting motion) the handle until the 'dot' lined up at the #1 position. Mantic59's youtube video, mentioned above, will give you a visual of this.
 
My progress is pretty much well calibrated but it starts on 5+, instead of 1. So, it seems the start is "-0.5", which means my setting may actually be 3 instead of 2.5.
 
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