Hello all,
I took all the replies to heart and am gonna stick with the bone scales. I am new to all this and would like to make these "by hand" (read: no power tools) as I don't own more than a grinder, jig saw and sawsall.

To my question: How important is it to have the inside of scale be flat/true? If paramount, what are some ways I could achieve this with the tools I currently own?? (have been working on flat tile and placing the piece on it and sanding it down.....very slow, even with 60 grit). I am getting down to about 1/4" and about 1/16" off of being flat.

thanks for the tips!
Bret