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Continue to the other side:


Now here is where it gets TRICKY!

Go UP in sandpaper grit and continue to sand. I use 400 to 600 or even 1200 depending on how close I am getting to the final shape.

REMEMBER if you go too far you have to start over again!

It is pretty easy to take off wood but not so much to add it! J

Sand a few strokes then test fit.



Sand, test, sand, ...

This is about how close you want to be right now:


Measuring up for thickness: This is GOOD!


Make sure they are pretty even on both ends:


What we have so far:



Here is a GREAT tip I came across after doing multiple scales. Cut some sandpaper in long thin strips: ...

Back to the sander:




Get them close to your final shape:



The scales LOOK longer
here but I think it is an optical illusion.
Maybe because they are smoothed out?





Drill the pin holes:

I Tape the original scale to the top ...

How I make Duck Scales:




Break down the razor:




Make a template of the scales.

I use masking tape to transfer scale design onto wood:

If you have a scanner you can scan them also. Holes show up nicely.


NOTE: Make sure the
scales have not SHRUNK!




Cut out a rough shape:
...