For the new scales I choose 3mm thick carbon fiber, which is tough and can withstand the abuse better than the original plastic injection moulded parts.

With the scales removed the knife was fully examined, cleaned and polished, paying particular attention to removing all the grit and debris out of the spring bars.  I used a solvent free cleanser to remove the majority of dirt (taking into consideration that this knife has a plastic magnifying glass as solvents can attack polymer based materials).  The final stage of cleaning was to wash the components in hot soapy water followed by an air blast for a final clean and dry.

With the knife clean all the joints and rivets spring actions can be assessed.  Where the handle had actually cracked and broken the liner had suffered the impact damage thus burring the liner and causing tightening upon blade opening.  With Swiss files and a flat punch the liner was straightened and cleaned up. 

All knife implements were checked for all working features: blades were re-sharpened and pivots & springs lubricated.

The new carbon fiber scales were drawn round and ruff belt sanded down to within 1/32” at the point.  I spotted the location holes from the original scales, (remembering to pick the right side of the knife!)  with a spot drill that did not go through the scale.  A dummy fit showed the scales fitted fine and gripped upon the rivet heads in position so I finally scribed around the outer liner & marked the scale and gave it a final belt sanding.  After fitting I set the left hand scale upon the milling machine to cut the slot for the tweezers.  This hole was cut to 3mm wide 19 mm deep and over length.  The open squared off and the end was finished off with a file to give a slightly push fit on the tweezers head. 

Fitting the scales I used 2-part epoxy thinly spread on the inside of the scale and into the rivet holes.  Both scales at the same time were fitted and clamped into place.  The excess epoxy was then removed using acetone on a wet rag.  After a curing period of 12 hours the scales were finally reduced and polished to give an appealing feel to the knife.  I kept the radius on the outside profile of the scales smaller to give strength and top the edge of the carbon fiber as shown in the illustration

Finally I engraved the customers initials on the knife as requested and filled it with silver inlay.  Just one final clean and polish and it was job done – a new knife!