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Old 12-18-2019, 09:24 AM
Rudy4 Rudy4 is offline
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Join Date: Oct 2012
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I use a combination of a small "back saw" that I reserve for "roughing in" the slots, skewing the blade to widen the slots where needed.

I also utilize a piece of stainless hobby flat stock that's .015" and rounded on the edge.

I first cut slots and then wrap and hold 220 sandpaper over the rounded edge to finish the rough cut slots and create the smooth and rounded bottom. Wider slots simply get 2 or more layers bent over the edge of my "slot tool". The smallest slots can simply be finished by doubling over a piece of sandpaper to smooth the slot and round its bottom.

I've done it that way for many years. I'd purchase good nut files if I cut slots all the time, but it's not a daily endeavor for me.

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