Often misused and not very well understood – so goes the life of many metalworking files. Yet, they still do things other tools cannot. That makes them a tool worth knowing!
Here are a few quick references to great information about metalworking files. Rather than re-creating an educational piece on the subject, for this Mechanic’s Tip it seems a better approach is to simply point to some awesome resources already available.
Metalworking files – also called Hand Files, or Abrasion Sticks, (or a bunch of other names) – are really very simple tools. They date back a very long time in various forms, and have seen fantastic refinement along the way. All the refinement and all the specialized variations make these tools extremely useful – but knowing which to use, and for what is the key.
There is a ton of great technology and thought in every metalworking file from years of product development by many smart people. For some history and a generic overview, check out this page on Wikipedia.
Use & Abuse of Metalworking Files
These simple tools (or should I say sets of these simple tools) are capable of so much in the do-it-yourselfer workshop. Yet, they are often abused, or misused – yet damaged files will not work right, so they go often go unused.
How many metalworking files do you own? How many different kinds? Or sizes? And, how often do you use them?
I have to admit, I have a lot of files. Big ones, small ones, metalworking files, woodworking files, even some power files. And, I use them all the time. I find them very valuable for so many things.
Yet, I will also admit, I am not so nice to my files all the time. You could use the word abuse, sometimes. I think that is what you call it when you use something in a way different than the intent.
While abusing tools is a poor admission, that is not the focus of this article. And, though it is not the best thing, plenty of great folks are always happy to sell me a replacement. 🙂
A Good Video
Here is a short video that gives an introduction to various types of metalworking files and cuts. The video then shows some cool tricks for using them. Even if you use files a lot, you might find a new trick here. And if you don’t use metalworking files much, the general information is still great. Thanks, Gough Custom, for the video.
I work with and teach kids stuff in the workshop fairly frequently. Proper use of a metalworking file is just one of the topics recently, so these are some tips to share. Learning to use the metalworking file right is the key to success with it. Of course, that is true of most tools, but it seems the simplest tools get the most abuse.
For example, think of the many ways a typical flat blade screwdriver will function that does not include screws. Oh, but I digress. Yet, files are used (and abused) in much the same way.
Here is another resource that shows variations in metalworking file types along with how and why you might use them. I like the illustrations and explanations.
Finally, there are a bunch of weird file types for specialty applications. We will not go into them – except one that is very useful, but not so common in the DIY-ers shop — the thread file. Check out this video as an introduction. (The author, davemotohead1, does not use a very careful technique, but look past the goofy stuff and he has the right idea.) Very useful.
Practice Makes Perfect
Metalworking files are not the easiest tools to become super proficient with. Sure, they are easy to begin, but mastery of the smooth stroke and fine finish is a skill to develop.
Metalworking files take some time for skills development – to teach your muscles to always hold them straight through the stroke. Practice a little with these tools, and realize that though they are ancient, they are also extremely well refined. Many great minds have honed the technology over centuries.
Take some time to teach yourself to use a file well, and you will find they are great for all sorts of things well beyond simple deburring (which is what most people use them for). The right tools, and in this case, the right skills with the right tools for the job make everything easier. And, help you achieve a better end result.
Here is a piece of odd knowledge: Did you know that metalworking files are some of the flattest tools in your shop?
If you need, you can check flatness of something by laying a file on it, then by look through at light between the file and part. A file will show you the flatness (or not) of the object in comparison.
Also, because they are really flat, they are a great way to finish up a part that needs to be pretty flat. Specifically I am thinking about wood parts more than metal ones. It would be really hard to finish a metal part to flat with a file.
Need More From Your Metalworking Files?
Going beyond the typical metalworking files takes us to the power tools incarnation of the “metalworking files” technology. If you want Danger with a capital “D”, these power versions will give it.
These short cylindrical files, like in the photo, are “Rotary Burrs”. Dangerous, because this is one wicked tool! Does it look nice enough? Not only will it will eat anything it touches, but it can whip a tool right from your hands, or worse, shatter in splinters all over. You must keep these things in control.
This one is carbide, and it eats steel. It devours aluminum, but, interestingly, it burns on wood. Super cool tool, but nasty just the same.
While I love this tool because of what it does, I have a huge respect for it. Control is the key to avoid bloody knuckles, or much worse.
I use this tool frequently for shaping and fitting metal parts. It is so easy to shape a plastic piece, or aluminum, to fit into a prototype, for instance.
Not for use by people with shaky hands. The one shown in the image is carbide, made for metalworking, and it eats steel, aluminum, plastic, and wood, (or fingers) for lunch. Please do Be Careful.
Get out in the shop and Enjoy A Reintroduction to the awesomeness of Metalworking Files.
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