Making Straight Razor Scales

Jim asked me to put some scales on a few of his razors.  One was a shavette, something I have never attempted.  It certainly is a little more involved.  Here are the steps I took.  I recommend doing a little research on any of the steps that you don’t feel comfortable with.  Feel free to ask any questions as well.

  1. I use  Plexiglass Acrylic sheets for my scales.  They are the perfect width, come in every color under the sky and are easy to work with.
  2. Trace or draw shape on scales.
  3. Ruff cut out with Coping Saw outside the lines.
  4. Dual sided tape the pieces together.
  5. File or sand the sides to the lines from step 1.
  6. Ruff shape the scales being careful to keep both sides symmetrical.
  7. Refine the shape with sandpaper.  I use 220 then 400 grit wet dry.  Doing this under running water keeps the paper cutting longer.
  8. Carefully slide or pull apart the scales using a razor blade to cut the tape.  Go around  the sides once with the razor before attempting to slide them apart.  Using WD-40 on the razor will prevent the tape from re-gluing as you cut.
  9. Ruff cut a wedge out of a hard material.  You can use the acrylic sheet something or like Delrin. I use a white spatula from the Dollar Tree. If the plastic is too soft, the next step is almost impossible.
  10. Sand or file a wedge shape with the wedge.  The angle will depend on how wide your blade is and how deep you want it to sit in the handle.  Be sure to check every now and then.
  11. Smooth the inside of the wedge before gluing.
  12. Glue the wedge in with crazy glue.  Be very careful as the glue will bond almost instantly on contact.
  13. Shape the end of the wedge to match the end of the scales.
  14. Drill out the pin holes.  Use the same size bit as your pins.
  15. Use brass pins and tiny washers to pin the scales and the razor.  I recommend practicing peening on scrap acrylic.  You will tend to hammer too hard at first.  There are lot’s of how to’s on the internet.
  16. do a final polish using a polishing compound and a soft cloth or paper towel. I use MAAS because I have it.  Brasso or a car polish would also work.  sand the peened pin ends and polished them also.

This is not a definitive guide or even how to.  I just wanted to share the steps I do.

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