Thought I'd post a little montage and describe how I did this, my first Mule (and first Syderco). I ordered a set of 1/8" olive drab green canvas micarta scales from ebay. My design is for a fairly lightweight hunting/skinning knife. I first traced the knife outline onto one scale.
Next, I used double-backed tape to hold the two scales together as I worked on them. I used a coping saw and cheap counter-top vise from Harbor Freight. Yeah, that's our kitchen; don't tell my wife
. I just roughly sawed around the tracing, being careful not to get too near it.
I formed the area of the handle at the bolster in more detail, filing and sanding this, as it would be difficult once the handle was assembled, as the knife blade would be in the way. Notice the mask, you don't want your lungs caked with this stuff
After sawing around the tracing, I clamped the scales and the knife to a 2x4 and used the knife holes as guides for drilling. This ensured perfect alignment. Just used my cordless drill, as I do not have a drill press.
For the lanyard hole, I used the rear 3/8" hole and brass cut from a .233. Would you believe that the diameter toward the primer of a .233 is exactly 3/8"?
Next, I separated the taped together scales and tested the fitting of the pins. For the pins, I used 3/16" brass rod cut with a hacksaw. To adjust the length of the pins, I used a diamond wheel on my rotary tool. I scuffed up the insides of the scales and added a few divots to help the glue stick. I also scuffed up the steel of the knife handle.
Next, I use two plies of tape on the outside of the scales to keep glue off of them and protect them from clamping. I decided to use Amazing Goop glue instead of epoxy because if I made a big mistake, I could conceivably remove the scales without destroying the knife.
Amazing Goop is an interesting glue, but somewhat difficult to use. You have to apply it to both sides of the items you want to adhere and wait 2 minutes before pressing the items together. Then it is difficult to align after pressing together. So the best way I figured to do this was to clamp the knife in the vice and lay the two scales on cardboard nearby. Then apply glue to both sides of the knife and to the two scales, rubbing it around with rubber gloves. After the required 2 minutes, I pressed the pins and lanyard tube into one of the scales and then inserted the other ends into the knife handle. Then I pressed the other scale onto the pins sticking through the knife handle. Finally, I clamped it all together. Note the tin foil I pressed into the lanyard tube to keep glue out. Probably didn't need to do this, as this glue is fairly easy to peel off metal.
From here, I used only files and sand paper (100 grit, 400 grit, 1000, then 2000 grit) to shape the handle. I'm very please with how it turned out. It weighs 3.7 oz on my scales. Keep an eye out for my kydex sheath build
Note the OD green webbing. Can you guess what project that will be used on?