drilling pin holes in irregular antler scales

[Jon Shade]

I have a nice pair of elk antler scales that I would like to put on a forged blade. The problem is that they are not flat. They are very irregular in shape. How do I drill nice straight holes for handle pins through irregular antler scales. Should I drill the pin holes before epoxying the scales to the blade or after? I normally drill my holes after I epoxy them to the blade using the pin holes in the blade as a guide. Thanks in advance! Jon

[Lin Rhea]

Jon,
    I assume that you are refering to the back or cut side of the scales not being flat. You first must flatten them. Then it depends on whether or not you have a guard/bolster to say the next step. If there is no bolster, just finish both scales on the front only, then glue on one scale. Set up a jig or cradle to drill the holes perpendicular to the centerline of the blade. Drill the holes, then glue the second scale to the blade tang. Drill through the first scale holes and out the second.

Then pin and finish the profile to match the tang.

This is very sketchy, but I am trying to answer the question as direct as I can.

[Jon Shade]

Thanks Lin! I have flattened the cut side of the scales already. I have not planned for a guard or bolster. So, I guess I need to build a jig or cradle that will allow me to drill the holes perpendicular to the center line of the blade. I assume I will be building this jig out of wood? That was the answer I was looking for. Thanks, Jon

[Lin Rhea]

Jon,
     You may have to use your imagination to get the blade horizontal. You may clamp the blade itself onto a wood block, then clamp the block in the drill vise. Play with it till it is square or perpendicular to the spindle. Then make sure to support the scale with shims or something so the scale wont pop off the tang.

There are some jigs that guys have made just for this purpose that makes it a lot easier. It holds things together and makes it easier to clamp in the drill vise. I think Master Bladesmith Steve Culver did a tutorial on this. If I find it, I will add the link.

[Lin Rhea]

Here ya go. Look around on this page and I bet you'll see what I'm trying to say, but better. Notice the Hanford Miller jig. Good stuff.
   
  web page

[Jon Shade]

Thanks Lin! You have been a great help! Jon

[Jon Shade]

Lin, I will be building a Hanford Miller jig tomorrow! Thanks a lot! Jon