Quote Originally Posted by Kyle76 View Post
Bruno, it sounds like you start with one piece of wood and make a "bookmatched" set. Is that correct? When splitting down the middle, how do you make sure each piece is the same thickness? You must use a saw with a very small kerf. What thickness do you start with, and how thick is each scale after the cut?
I use a standard swedish bahco saw.

I start with one block that is 23 mm thick and I saw it in half lengthwise. This is a tedious job.
Then I either use a beltsander (if I have acces to one) or a file and a plate with sandpaper on top to make the insides flat.
Then I use dual sided tape to stick both halve back together and then I use files, sandpaper and / or a dremel to shape the scales and to make them thinner.

Since both halves are stuck together, it is fairly easy to make them symmertical and of the same thickness.

As soon as the outer shape is ok I seperate the pieces and I do any necessary work on the insides if I need to.

This way I end up with identical scales that fit together without any problem.
The key here is that when I start filing / sanding, both halves are way thiccker than whay I need so I don't have to care abou the initial thickness.