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i use metal rasps/files to thin out my scales and shape them down.
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i clamp them down between a board and the tabletop, then go to town. it takes some practice to get them even, but with sandpaper and patience assisting you, you can do it.
vgod
I cut out a set of Bocote scales today. I started with a 2x6x3/8" block, and first cut it into two 1x6x3/8" blocks, then cut that in half. Then, taped sand paper to my kitchen counter:) and sanded away. I now have ~1/8" thick bocote scales. I have to say, it was much more difficult than I though it would be. The difficult part was sanding perfectly perpendicular edges to the sides, and the inside curve of the scales.
I use boards then re saw them down to 6x1.5x?? blocks then resaw the blocks into 1/8 blanks on a bandsaw with a ½ inch blade. Then sand them on a large freestanding 6 inch belt sander to remove the mill marks. That takes them down just under 1/8 inch. Then I can start making the scales. I use a drum sander to sand down the scale shape after I cut them, then do the shaping, final sanding and finishing.
Related to this topic, where's the best place to source scale hardware (pins)? I'd like to do the adjustable screw at the pivot end, preferrably with the decorative dealie like some I've seen on here. Need the fixed pin as well though.
I took a piece of 2 X 3/4 inch mahogany to a store that makes custom cabinets and furniture and asked them to rip 1/8" off. They did it for free. Then I cut out the scales with a coping saw and sanded them to shape.
Doug, NYC