Horn Scales For a Stub Tail Greaves

[mycarver]

I've had this razor kicking around in my to do pile and I wasn't sure just what to do with it.
Granted I could just whip up some scales in Horn and call it done. Nope.
Wood? Well,, maybe.
Micarta? Never.
Repair the originals. Nope, ain't gonna happen on this set.
So I figured why not try to copy the originals?
So I tried. Not perfect but it's mine and I'm quite happy with it. Not the normal run of the mill.
And as they say if you please yourself you've pleased at least one person!

I'll use a few photos here as I chronicled the process somewhat.
I first grabbed some slabs of Honey Horn and selected my favorite sections. Got the slabs flat, traced the original scales and cut out the blanks.
Then used my calipers to duplicate the taper of the scales and also copied the radius of the surface to my blanks.
Same old , same old ,, making scales to this point.
As you can see on the originals they have ribs, for lack of a better term running their length. I transferred this design on to my blanks using a straight edge for guide lines.
At the hinge end they were just around 3/32 and grew to 1/8 at the wedge end.
I laid in these grooves with a disc grinder freehand following my guide lines. Then I had to create a true V groove instead of the square bottom channel the grinder left. I used jewelers files and single edge razor blades as scrapers to refine these lines. Also I used an old straight edge razor with sandpaper wrapped around it to make a very fine sander.
Once the lines were refined it was a matter of rounding over the ribs to mimic the originals.
At the wedge end , as on the originals, the lines flared out creating a nice effect. I did this free hand as well.
In the photos you'll notice I cut through the end. I didn't care as this would be further refined when I used the original wedge and pinned it.
Once all the sanding etc. was done I went to a variety of compounds on the buffer for the final shine..
On the blade itself I decided not to take it to a mirror finish. This has some history and the original I"m sure wasn't finished to the level I could take it to. Grind marks were left and I finished it with a rather course sanded texture as evidenced by the finish I could see on the original surface.
Lets face it, a blade this old wasn't ,, and won't be finished to a high degree. I do have some reservations as to the scales looking too "new" but since it's my razor ,,,, I can live with that.
Less talk,, some photos showing my progression.