Thread: Need to have tools for rescaling

This is a necessity list of stuff i use to convert boards to scale.
marking gauge
270mm Japanese rip saw.
42mm plane; 36mm scraper plane
coping saw
16 inch double cut file
10inch 1/2 round file
sand paper
gimlet / hand drill
hammer w/ small anvil
whittling knife
chisel and gouge for wedgeless designs
tite bond III wood glue

- i use different knives or gouges; sometimes a small finger plane, smaller file, etc. That's about it

Originally Posted by BJC

Dan gave a wealth of information above. I just recently started making my own scales. In fact, the first set of scales will be pinned in a little while. Since I constantly travel, I chose to do mine by hand. Here is my experience thus far; take what you can and leave the rest.

1) Scale stock - Take your pick of bone, plastic, wood, etc... Whatever you do get it milled to 1/8" when you order it. I originally bought some wood by the board foot, expecting to be able to cut it down myself. After many hours of labor and no success worth mentioning, I ordered some blanks from Rockler Wood online. Prices are reasonable, especially if you order the maximum amount of wood for a particular shipping charge. 6" X 1.5" X 1/8" have worked well for me.

2) Tools: Since I chose to do everything by hand, my tools are limited. I have a small ball peen hammer, a rasp/file combo (comes is handy for quick work shaping by hand), a 6" coping saw, plenty of sand paper in the grits listed in Dan's post, a small rubber eraser (makes a dandy little sanding block), a hand drill (haven't used this yet - I cheated and used the power drill since I was home), and carpet tape (for adhering the scale blanks together)

3) Process: Outline the scale shape you want, cut rough outline with coping saw, refine the shape with the file/rasp combo, final shaping with sandpaper, prep wood for finishing, finish with your choice or epoxy, poly, etc..., pin the new scales and blade together, hone, strop, and enjoy!

These are almost exactly the same tools I used to make my first set of scales.

I have to emphasize the 'hand tool only' method is quite time consuming but is very rewarding.

I also used a gents saw to do some rough cutting.

Using the rasp and file is a sure way to avoid a slip and ruin your scales; because it is slower (don't get me wrong a sharp rasp can cut very quickly for a hand tool) than a sanding station with drum sanders etc.

I also don't have a vice (at present) and the double sided tape helps with the initial cutting a shaping of the scales material. Stick the material to a scrap peice of plywood and saw away!

I was using birdseye maple and boy of boy is that tough to work with dull tools. I had to sharpen my saw and use fresh sandpaper throughout.

It doesn't have to be a big ordeal and can take only a few hand tools to accomplish!

I'm really in to just using handtools to.I get enough of powertools at work...Did you buy tose tools at DICK ?(Its a real name)

Sometimes I will use the vise on my work bench to rip.Usually I can just hold the small piece against a stop. More often, i use the vise to hold a plane upside down. With the small, thin size of the material it's easier to use, planes, and the big file as stationary tools while holding the work piece in you hand. It usually takes me both hands to guide the faces of the scales over the cutter. But there are other ways to secure the tool without a vise.
I left a fine cross-cut saw, sharpening stones off the list. oops. I have never used D_B, but mine come from several sources.

When you have the right tools, this work is quite quick and easy with hand power

After all, man has been able to do amazing work with handpower long before the industrial revolution.

If you want to use carbon fiber, you will need a jig saw and a ceramic tile blade. After that you can sand with wet and dry paper. Low grits up to high grits.

They look great when done but the raw material isn't cheap.

One more thing, for the sake of your health, it's wise to ware a dust mask while you are cutting and sanding.