I decided to remake the knurler with cold rolled steel. Above, you can see the dark scale and rounded edges of the Home Lowes crap steel. What you can't see is that it also varies in thickness several thousandths over the length. Below it is the bright finish cold rolled Gem State steel with nice sharp corners and consistent size within .001". This should make for a smoother and more accurate tool.
Now I need to learn Google Sketchup so I can make my design changes without ending up with a knurler that doesn't work after I've made it...
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