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Glen, I must have misinterpreted what you meant but the part of your post that said
'...then after the holes are drilled, I split the two scales apart and thin them down from the back side only,...

Glen. I have to disagree with your conclusion here. I've attached a picture of some scales that I made using exactly the method described earlier and I don't think they look like Popsicle sticks. The...

That's a good idea but I assume you need a fairly regular blank to start with. The great thing about the luthiers friend is that any difference in thickness or even warping is automatically sanded...

Well, I wish I had your abilities - I had to buy one from Stewmac AND have it shipped to the UK. It was after using this that I started to have the scales a lot thinner than I had previously. Before...

I find it much easier to sand the required thickness before cutting the scales. I've done this by using double sided tape on a piece of board and then using a belt sander - taping to the board helps...