re: scale shaping - how to make consistent beveled edges ?

[sloanwinters]

i feel like im able to make rounded scales that i am desiring in many shapes and sizes, but the flat-sided with a 'beveled' edge still eludes me. i can get a (fairly) consistent beveled edge all the way around the scale initially using a vertical belt sander, but when i move up the sanding progression, or especially when i put the scales on the buffer for a final smooth-n-polish, i lose the hard edge and soften the line between bevel and (flat) side. i hope i am making sense and explaining properly.

i was thinking about maybe using a drum sander but i would also need something else to rest the scale against to ensure the same uniform bevel angle. i was also considering a router as the router bit itself could impart the desired angle. but again, once i take the scale to the buffer ill most likely lose that nice hard edge between the two.

so my question is this ... how are you other scale makers out there able to put a scratch-free polish on your scales without ruining that nice clean separation between the flat side and the beveled edge?

any advice would be greatly appreciated.
thanks!