Need Help - GB Scale Set - How to shape the wedge?

[gaj90027]

I purchased 2 sets of pre-cut scales from Ray at Gentlemen's Best to rescale a really nice Sheffield 5/8 full hollow

http://gentlemensbest.com/TheScaleShop.aspx

I got replacement scales set #5 in both Lace Wood and Birdseye Maple because I couldn't decide which material I liked more I also picked up 1 each of the Buffalo Horn and Natural Bone 1" x 1" square wedge materials to see which I would like better.

Anyway, I understand the process and tools needed for finishing the scales (sanding, staining, etc) and pinning the scales but I am completely lost on the best way to shape the wedge material.

Any tips and tricks on how to shape the wedge material, including what tools to use would be greatly appreciated for this first rescaling project of mine. Would a dremel with a sanding wheel bit work with either of those materials or do I need to sand by hand?

 

[heirkb]

A dremel with a sanding drum works in giving the wedge it's wedge-i-ness.
Cut your wedge to a rough approximation of what you want (cut off wheel, saw, whatever works...). It doesn't need to be and shouldn't be dead on, but you want it smaller than a 1"x1" square to speed up material removal.
Take the sanding drum and draw it across parallel to the edge that is going to the thinnest part of the wedge. I hope that makes since. It's like beveling the edges of your scales, but you want a much flatter angle.

Here's an illustration: View attachment 116781

So the first drawing is of the material at various angles. I drew a square and you can just go ahead and follow this process with the square you have, but again, you could cut it down to approximately the shape it's gonna be in the end so that you don't have to worry about removing as much material.

The next drawing has a darkened beveled area, which is what you will have done with the sanding drum. That edge will be the thin part of your wedge. You don't want quite that steep of an angle though, or else your wedge will come to a point and look like a full on triangle from edge on.

Once you've done this initial "beveling", it doesn't take too long (5-10 minutes) to finish the wedge shape. Lay some sandpaper down on a flat surface and apply pressure to the area that you just beveled. Keep on sanding until you get a wedge shape.

 

[Obiwan]

That was very helpful. I just had the same question myself.

 

[r0ckrat]

One thing I would do is work on a piece that is a lot longer than what the finished wedge will be, then cut off the excess. So like in the illustration above, the actual wedge would only be the first 1/3 or 1/2 of the material. Gives you something more to hang onto while sanding the angle. (Or, bevel the other side too, and have two wedges from that piece.)

 

[BillEllis]

http://www.youtube.com/watch?v=Gdau4m_4x-U

You can use a piece of sandpaper on a flat surface if you don't have equipment.

You can also use a piece of wood with a wedge cutout put in place using a wood chisel to cut the cavity. Then, use a wood rasp to file the wedge material that you have placed in the wedge cavity of the wood.

Fine tune with the double sided tape thing and a piece of sandpaper on the flat surface to sand to shape.

 

[heirkb]

Really good idea, Bill.

I bet you could also use a file in place of the dremel in the method I listed above. Just do the beveling with the file and sand the wedge on a piece of sandpaper on a flat surface.

 

[azmark]

I use a dremmel and belt sander. Just make sure the wedge is secured tightly to the scales and run your dremmel over the material to make it flush as close as possible. The last 1/16 of an inch or so I take a file as Mr. Ellis has said and it helps me get close without running the risk of damaging the scales.

A word from experience using a dremmel, it will get away from you if you're not paying attention for the slightest second. Secure your scales and go slow with the dremmel.