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Were the scales parallel when you drilled the hole? I usually put a spacer between them when drilling of approximately the same width as the blade. I also make sure I am holding the whole assembly...

Nothing wrong with holding the razor in one hand and the dremel in another. I usually wrap a piece of masking tape over the edge of the blade when working on a razor but many times remove scales...

Yep, that's it. And you're right, a smaller diameter is better, but once you get the hang of it you can do it with a new, full-size wheel without damage to the scales.

For removing old pins, I've found that the dremel with a cutoff wheel works best. Carefully bring the edge of the cutoff wheel down onto the end of the pin and score it in about three places, then...

The ebony replacement scales I got from CS already had the hole. The only problem you might run into is the collar fits tightly. The pin itself is like a nail with a point. I drilled a hole into...