The Benchmade Bugout is a fantastic canvas for customization. Swapping the factory scales for a premium set of Aimfront scales is one of the most satisfying upgrades you can make, instantly elevating the knife's rigidity, feel, and style.
While it might seem intimidating, this process is surprisingly simple with the right technique. Forget a full teardown where parts can get lost. We're going to walk you through our proven one-side-at-a-time method. This approach keeps the knife's internal components perfectly aligned, making for a smooth, frustration-free installation.
A quick word on safety: Before you begin, always ensure your knife is clean and dry. Work in a well-lit area on a clear surface and take your time.
Tools You'll Need
Having the right tools is essential for a clean installation without damaging your knife or your new scales.
- Torx Drivers: The Benchmade Bugout uses two sizes. You will need a T10 for the main pivot screw and a T6 for all the smaller body and pocket clip screws. A quality driver set is your best friend.
- Threadlocker (Optional but Recommended): A small amount of non-permanent threadlocker prevents screws from vibrating loose over time. We recommend Loctite 242 (Blue) or Loctite 222 (Purple).
- A Clear Workspace: Use a magnetic parts tray or a simple mat to keep track of the small screws. This will save you a headache later.
Installation: The One-Side-at-a-Time Method
This method is the easiest and safest way to swap your scales, ensuring the blade, washers, and axis lock stay perfectly in place.
Part 1: Replacing the First Scale
- Remove the Pocket Clip: Use your T6 driver to remove the three screws holding the pocket clip. Important: The pocket clip screws are a different length than the body screws, so keep them separate.
- Remove Body Screws: On the side with the T10 pivot screw, use your T6 driver to remove the two main body screws.
- Remove the Pivot Screw: Use your T10 driver to unscrew and remove the pivot screw.
- Install the First Aimfront Scale: As soon as the pivot is out, take the matching Aimfront scale and fit it into place. It should align perfectly with the standoffs and liners. You may hear a satisfying click as it seats.
- Loosely Insert Screws: Re-insert the T10 pivot screw and the two T6 body screws. Snug them up, then back them all off about a quarter-turn. This keeps the assembly together but allows for adjustment later.
Part 2: Replacing the Second Scale
Now, we'll repeat a similar process on the other side.
- Flip and Remove Screws: Flip the knife over. Use your T6 driver to remove the two body screws on this side.
- Push the Pivot Through: This is the key step. Slightly press down on the axis lock bar to relieve tension. Now, use your T10 driver to push the pivot screw through the knife, leaving the driver in its place. This brilliantly holds the blade, washers, and axis lock in perfect alignment.
- Swap the Scale: Remove the old factory scale and set it aside. Place your new Aimfront scale into position. Make sure it sits flush and lines up perfectly.
- Re-insert the Pivot: Pull back slightly on the axis lock bar. Notice the small flat "D" shape on the head of your pivot screw—this aligns with a matching flat inside the knife liner. While gently wiggling the pivot, push it back into the knife, forcing your T10 driver out the other side. You'll feel it snap into place when aligned correctly.
- Secure the Hardware: Screw in the T10 pivot screw until it's snug. Then, re-insert the two T6 body screws, snugging them up and then backing them off a quarter-turn just like the other side.
Final Adjustments for Perfect Action
This is where you dial in the performance of your newly upgraded knife.
- Center the Blade: With all screws slightly loose, close your knife and look down its spine. If the blade isn't perfectly centered, gently push or "rack" the handle side-to-side. You will see the blade tip move. Once it's dead center, hold it there.
- Set the Pivot: While maintaining pressure to keep the blade centered, tighten the T10 pivot screw until it's firm.
- Tighten Body Screws: Now, tighten down all four T6 body screws firmly. This is where you can add a tiny drop of blue or purple Loctite if you choose.
- Install the Pocket Clip: This can be tricky. A great tip is to place the three small T6 screws into the pocket clip holes first. You can then use the clip itself as a handle to align the screws with the holes on the scale. Tighten them down. We recommend using a drop of Loctite here, as these screws tend to loosen most often.
- Tune the Action: Open and close the blade a few times. Check for side-to-side blade play. If it's a little loose, tighten the pivot screw in very small increments. If the action is too stiff, loosen it slightly. The goal is a perfectly centered blade that opens smoothly with no side-to-side wiggle.
Your Custom Bugout is Ready
That's it! You've successfully installed your new Aimfront scales using a professional method. You've not only transformed the look and feel of your knife but also learned a valuable skill. The result is a rock-solid, high-performance EDC tool that is truly your own.
Ready to start your Bugout project or looking for your next upgrade?