First time to do a 58mm scale. Usually the guides found in the web are for the 91mm models. But most of the techniques can be applied to the smaller version.
First off, I disassembled an old 58mm classic with a badly damaged blade. I need the liners to act as a drilling guide and a shaping guide later on.
Make sure the wood is already close to the final thickness and size you want it to be, just make it a tad thicker (~0.2-0.3mm thicker) and bigger so that you have some material left for final shaping and sanding later on.
After having the rough shape, use one of the liners to make pilot drill (I used 1.5mm drill bit) on one of the four holes first. Please set up your drill press to the proper depth so as not to drill through the thin wood. I drilled just enough for the old pin to be inserted. I inserted an old pin into the liner+wood to keep the wood aligned to the liner on one hole. I then proceeded to drill another hole on the opposite corner (same depth) and pushed another pin there as well. I then drilled the two other holes. This technique ensures that the holes are perfectly aligned with respect to the liner. NOTE: If you have a clamping mechanism that clamps the wood and liner together during drilling, you don't need to follow the steps above, just drill the four holes at once.
Next step is to increase the diameter of these holes, the diameter of the 58mm bushing is around ~3mm. I used on of my dremel carbide burrs that's close to that diameter to enlarge the holes to the proper size.
Using the other liner, I inserted the pins and bushing into the liner and use blu-tack to hold it in place. I lost the 4th pin so I only had three at this instance. I used this as a guide to sand the wood scale to the final shape required. Again, if you have a clamping mechanism that will enable you to keep them together during sanding, you don't need this.
The wood scale with the liner attached. I outlined the liner with red marker to easily see the edge :)
After several passes on the sanding drum I have the final shape and thickness. I used my previous technique of attaching the Victorinox metal shield to attach it to my wood scale.
It's simple, I put a very small amount of 2-part epoxy (colorless in this case), on the metal shield (make sure it's just enough so that there will be very minimal excess later). Carefully align the shield to the wood, using other 58mm cellidor scales as visual aid. Gently press it to tack it to the wood. I then sandwich the wood with the scale into two pieces of metal to ensure that it is flat and then I press it with my table vise for about 5-10 minutes. I found this method ensures that the shield is pressed firmly into the wood and minimizes the "embossed"-effect.
I attached the wood scales to the liner using contact cement glue (shoe glue/rubber cement/rugby glue). This has a reasonable amount of strength while still enabling me to remove it without damaging either the scale or the liner. I clamped it (using some cloth to protect the wood scale from damage) on my vise and have it set overnight.
Ready for you!