Next time you have to remove some scales, you can try letting the warm up in hot water first. Syph007 mentioned that in his mod thread and I've used that technique with good success as well.
Good tips jaya_man I've tried the hairdryer/heatgun approach but found that the warm water worked better in getting the insides of the scale to be flexible.With the air, it tended to heat up the outside and tools quickly, but the inside of the scales was not as pliable. Maybe the soak time (like when you use the laptop/computer fan) is what is needed for that to work.Taking the time to mock and test accessibility is huge. Has saved me much hassle and wasted material.Also, be patient with peening. Go light and slow. Check frequently for tool tension and play.Good luck with the mod and make sure to post pics and thoughts on the process when you're done. Always interested in seeing what others come up with.
That looks like a substantial loss of material.I've found even small amounts of material loss (and probably some stretching/bending) when removing the scales is enough to reduce their ability to snap on again.I doubt they will snap on like new scales would. You can try press fitting them on when your mod is done. If they don't snap on, they should be usable if you add some glue and clamp them on.Usually I will just use a small dab of gel superglue and then clamp the SAK and let it set for a few minutes.Next time you have to remove some scales, you can try letting the warm up in hot water first. Syph007 mentioned that in his mod thread and I've used that technique with good success as well.