A timely thread.
Thx OP
I use Kutzall burrs in a drill or a jeweler's screwdriver to make the indents for screw heads. Drill bits, as already mentioned, are another option when used carefully.
With the location of the M15 screw, #5091 in the shop manual,
I would just remove a bit of wood.
I have a bunch of side plate screws so I screwed them in after drilling 7/64" holes in wood and filed one down. One is still OEM.
Pic of grip made for a 460, shows how close the other side plate screw is to the end of the wood, blue marker.
The 460/500s and other Smiths come with Hogue rubbers, so it's not an issue.
The rear screw is the same as the other screw but countersunk a bit deeper.
Grips were bedded and will be masters for duplicating. I'll be adding some powdered white wood and epoxy to add on and reshape that part of the grip.
Other option is making the screw heads flat. Just did one to see if the remaining slot is usable.
Not the best option for making grips for family and friends.
Will try using the Kutzall wheels to remove wood for plunger tube clearance. Grips set on mill and see if it works.
Beats sawing and hand filing as we did with 2K sets of slabs long ago.
The incubative years, as I told Mr. Pachmayr,
during a fun conversation.
