Thread: Horn Scales For a Stub Tail Greaves

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.

Excuse the length of this but I was having a ball!
As you can see I got the scales roughed in and then went on to further refine the design. Once all the sanding was done you'll see here how I got them polished.
To finish the razor the original had brass pins and steel washers. So I used brass and double stacked SS washers to mimic the look.
The blade honed up just fine and was easier than I anticipated and I just can't wait to use it.
Now granted this isn't the most perfect copy of the original scales but I believe I achieved a reasonable approximation of them. I'm sure the razor is much happier with the new scales and I'll have no problem using it. And at this level of magnification with the camera,, flaws can be easily seen. But with the blade in hand, to me, none of it matters. I'm a happy guy.

Under most circumstances, I would've tried to fix even that break in the original scales... But your new scales are mighty fine work! I wish my old Acier Fondu Greaves was honable, but it's working days are over, I'm afraid.

Bravo!

Those look great! You must have a steady hands. I would have had those lines all over the place.

I normally don't like this shape of blade and scales, but this seems to be the exception. Great job!

Ahhhh, something a little different! I'll bet you had fun! I love the results!

Good job!! The razor looks great.

Excellent work on duplicating/replacing those scales. Nice clean looking razor.

Those scales look awesome. Love the polished translucent look.

o wow !!!!!!!! one of my fav manufacturers with some amazing scales !!!!!!!!!!!!!!!!!! im in love !!!