Hey all, I've been trying my hand recently at making custom scales. So far, I've been able to get the wood cut to the right shape and sanded down rather well. But i've run into two problems, and any suggestions would be most appreciated:

1) I can't get the wedge to sit flush between the scales - i.e., so that you have three pieces of wood all pressed together into one solid piece. I guess it ha something to do with the wood not being perfectly flat - though they seemed flat - because I even had the problem with the factory made thiers-issard plastic wedges I tried. Is it possible that you just need to fully tighten the pins, and that cranks the wood together and brings them flat?

2) Some of the wood I have is a bit too thick, especially for making wedges. Are there any efficient ways to slim down the thickness? I dont have a table saw or anything that would work well, and sanding down 1/16" or 1/8" of hard wood takes forever. Maybe I need a plane, or something like that?

3) And when it comes to wedges, what thickness do you generally use? Those T-I wedges I mentioned are VERY slim, but I've also seen some "wedges" sold that are as thick as 1/8" or more. And is it necessary that they be "slanted" rather than flat, and if so how does one make them "slant", especially in a way that would result in both sides being slanted symmetrical?

Many thanks for your help, everyone -