I have been using 3/4 inch, but that would depend on the length of nick you want if just plunging for a "round" nick. You can travel for the desired nick length, giving you a flatter nick with pointy ends. You may need a bigger diameter in order to get a longer shaft for some knife blade patterns because the milling of the nick needs to be done with the blade spine down and on some wider blade shapes it can be quite a reach. Anybody else?
Try different shapes for the cut. Start with something that looks like a threading tool or one tooth of a dovetail cutter. Radius the point just a tiny bit so it doesn't make a sharp corner. Test in a piece of scrap.
The radius of the tool - i.e. how far out you have the cutter set - will affect things, too.
Tweak the geometry 'til it's the world's best nail nick.
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