OK, I think I have it finished. I swapped the steel screws for brass but they lack the required patina. I found that I had to chase the threads in the aluminum "nuts" with a 8-32 tap (load the tap with vegetable shortening or Lee case-sizing lube for aluminum) and they fit perfectly. The threads were so close you cannot tell they were touched. I also flared the back of the mounth of the sheath so the square edge of the PSK's handle - a fault of theh original sheath design, not the handle - I LOVE this handle.
And, thanks, Brett for the help with the photos!
So far, we have seen some incredible leather and some Kydex but I am waiting to see paracord wrap variations. This has been a very neat "idea exchange" forum and - "thanks for that," Scott. Aside from being an great knife - which has replaced a couple others I no longer need and have sold - it is also a great platform for exercising your creativity and personal preferences in carry options. If I could right now, I would have one of each variation on order, to include the "Sr." and the PSK/Tusk Hybrid but I have to spread them out a bit and hope the Kydex and leather supply holds out while I play with the two I have.