Well, it took one helluva long time, and a lot of different failed prototypes and tests, but, I finally made me a set of scales from carbon fibre.

Pics:
closed - close up - vertical - profile

The scales have a few very minor aesthetic flaws, but came out slick as hell, if I do say so myself It has a nice low profile too; the thickest part of the entire thing is just over 5/16" of an inch.

The scales are made from 1/16" thick carbon fibre sheet. I'm not sure the exact details but I think it's a triple layer twill weave 3k tow carbon fibre. Strong as hell, and, whatever resin was used is like cement. I added a few layers of CA to the outter sides so it could be polished up like glass. The blade sitting comfortably in the scales is a heljestrand.

These were the most difficult set of scales I've made yet. At the moment I'm doing all my cuts by hand with a coping saw. This stuff was harder to saw through than twice the thickness of any of the woods I have. It also dulled two of my coping saw blades Needless to say, I think I'll be staying away from it until I get myself a bandsaw or something similar. Also, Sanding makes the worst mess ever. It produces this fine powder that just turns everything black; it's like sanding a piece of charcoal.

I definitely want to make some more scales for a few of my smaller razors, but, this stuff is just such a pain to work with that I'm going to have to hold off until I can get some better power tools.