Makes complete sense, Pieter. I guess the only downsides are that it takes longer and that the epoxy "rivet"then consists of two parts, which might not be as strong - not that I think that is a significant issue with decent epoxy.
Tip: next time you need a file or rasp like that 4-in-hand in your pics, buy Craftsman brand ones at Sears. They'll replace 'em when they wear out. I do use Nicholson flat files so I can make blades out of them when they get dull, but I've started getting all my wierd shapes and whatnot from Sears.
That's the plan. I just want to get closer to my final shape. I didn't want to be constantly raking the pins with the wood rasp. Once I have the shape I want (and after I'm done working with the wood rasp), I'm going to epoxy them in. Then, I'll file the pins down, and finish sanding.
Great, my comment was completely in line with what you were planning in any case. I don't use a wood rasp much (I use a file, or the grinder/Dremel), which allows me to glue in the pins at the same time that I put on the scales. Same result in the end, so I guess it doesn't really matter.
Looks great so far, you are definitely doing this the hardest, and probably most fulfilling, way possible. I would suggest that when you set your pins that you spin them in a drill and use the sharp edge of a file to cut some rings in them to retain some epoxy. Since the original epoxy has fully cured the new stuff will not permeate the old and the pins will be slightly less than 100% effective.
I use a fixture to stack the scales will the pre-drilled blade on top and drill my pin holes through everything at once and when you epoxy everything at the same time, you get a monolithic bond where everything is supportive. If you choose to put your pins in afterward because of the hand rasping I would use a stepped Corby or Loveless style bolt to secure the scales.
Other than that, you should be commended for your hard work and great WIP.
Thanks for the kind words. I had planned on doing exactly that. My plan is to put the pins in the drill, rough them up with 150ish emery cloth. Then, take a file and, very gently, cut 3-4 rings in the pins (I already purchased them when I ordered the steel). They are 3/16" shamrock pins. I'm hoping they go along with the green scales.