The following filework can be completed using these files which can be obtained from MSC
Nicholson 6-1/4“ Swiss pattern files.
Marking file- #0 cut # 60304318 (course) no longer available from MSC
In place of the marking file, you can use a half round and grind the teeth off the flat side
You can find them here: http://shorinternational.com/fileshalfrd.htm
#2 cut # 60304326 (medium)
#4 cut # 60304334 (fine)
#6 cut # 60304342 (very fine)
Round file- #0 cut #60304425
#2 cut #60304433
#4 cut #60304441
#6 cut #60304458
Three square- #0 cut #60304698
#2 cut #60304706
#4 cut #60304714
#6 cut #60304722
First mark one side of your work with a scribe or dial caliper. The space you decide on will vary with the thickness of the material you’re using. On 3/32” material I usually use 3/8” space between thorns. I just mark one Side with the caliper & eyeball the other side. Do what works for you.
Step 1. After you’ve marked your work start out with your round file on a compound 45 degree angle. Cut the same depth towards the center of the blade as you go down the side of the blade. Keeping everything consistent makes all the difference in the world. Make sure to keep your cuts close to your marks.
Step 2. Now take your marking file or three square file that you’ve modified & make a cut just behind the cut you’ve just made with your round file cutting the same depth towards the center of the spine & down the side as you did on the previous step. Make sure you don’t cut too deep right off the start. You can always remove more meat later.
Step 3. Start with the course (#0 cut) marking file and start removing excess material imagining the dotted lines as in the drawing. Remember from the very start and all the way through to the finished product to keep your files on a compound 45 Degree angle.
Step 4. Now just keep on doing what you’re doing but gradually changing from the course files to your finer ones. Every once in a while take some 1000 or 1200 grit paper with a block and dress the burs off of the top so you can always see exactly what you’re doing.
