The best route might to bite the bullet and have it hand checkered.
Friend and I started making the hammers for Winchester lever actions (the 73s, 76s, 86s, 92 & 94s).
Biggest issue that we had was the checkering on the spurs. We originally had them hand cut, but that got pricey, looked at having the checkering CNCd, or having a stamp/roll made, but all kinds of issues with the compound curves.
Last batch we had the checkering burned in using an EDM type process. It looks very good and doing quantities is fairly low cost. But again we are doing quantities of a dozen each at a time.
Mike Hunter
