I have a new problem today. The smallest file I could find is a 1/4-inch and it won't fit inside my cork handle so I can't ream it out. Any suggestions? Thanks for the help. I'm a beginner. Bruce

I don't quite understand what type of file you are talking about. Is it a round wood rasp? The 10" wood rasp I use is tapered and varies in diameter from 5/32" at the tip to 5/16" at the butt and works well for reaming cork. They are available at any hardware store in various sizes.

I think the "official" name for the kind of file you need is rattail and they are round. The one I use tapers about the same as Bob's. The real trick to using them is to rotate them counter-clockwise. The teeth seem to be cut on a clockwise spiral so if you rotate them clockwise, the file gets drawn into the rip and can actually split it. Rotating in the opposite direction doesn't do that, it just removes material.

The rat tail file will probably just barely fit in a short distance at first. By removing cork, you gradually get it in all the way. Go slow. Also, instead of rotating the file CCW, it can be easier to hold the file steady and rotate the cork handle CW.

You can also cut the square end of the file off and chuck it in a variable speed drill and use as a power reamer (in reverse) I stick my drill in a vise and hold the grip so I can control the reaming speed. It works pretty well

Mike



Edited 1 time(s). Last edit at 01/19/2005 12:09PM by Mike Barkley.

You may want to get a chainsaw file as a starter file. They come in several sizes and a very fine toothed as they are made to cut metal. Once the hole is enlarged slightly, the rat tail should work fine or a tapered reamer........

Thanks All!
I couldn't find any wood rasps but I bought a 1/4-inch metal file. I was afraid to use it because I thought the cork might split. I called around and found a place that carries chainsaw files. They're 6" long by 1/8 inch round. Do you think it would be long enough?

i think it is too short and too small. you want to start with a small rat tail file that tapers to less than 1/4
but is more than 1/4 at its largest diameter. you should not have any trouble finding one at home depot or lowes. cut off the tang and chuck the tang end in a reversible variable speed drill. turn it counter clockwise and insert it in the cork and go. i have three of these files of various sizes and it gets me where i want to go most of the time. if i need to go larger i have some reamers.

Bruce ---
Home Depot, Lowes, Ace Hardware.... all should have the round (rattail) wood rasps that the folks above referenced. Metal file will work - but will "clog up" and cut much slower than a wood rasp.

Flex Coats arbor drills work great to get things close, then finish up with reamer.

Regards.

Regards......Doug@
TCRds

Check out Lee Valley, they are a Canadian supplier to the fine woodworking world. They stock an endless variety of files, rifflers and assorted power based cutting tools for Dremmel and similar small rotary tools. They have an online catalogue and store, try a Google or Yahoo search it'll come up.