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I tried wedging one-piece scales a while ago to make them wider, and then I broke them :banghead: I will have to experiment a little more (carefully) in that area.

Ah, yes, impatience is one of my virtues as well. Taking my time while pinning helped my overall pinning results, but not with the torque.

I tried thinning down the scales and that worked...

I got this problem with and without washers, although it was less obvious when I used them. I normally use wedges, but am currently working on a one-piece scale on which I want to prevent it.
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When I pin my home-made scales, I often find that the rotating resistance is not even along the distance that the razor is rotated relative to the scales. For instance, when one razor is opened...