End mill question

[AVigil]

Drill small holes, cut slot with Jewelers saw and then finish with files.

 

[Pinoy Knife]

i think the First problem might be a small enough drill bit to start the slot (just had this problem making "Broach tool handles"
i just cut the block in half /mortised it in and glued up (no visible line)
a Challenge i see is the need to start the slot for the broach to begin cutting (you need both a Push and pull cutting broach)
then having them thinner than the blade to prevent you "Over doing it" on the width.
hack saw /Sawzall blades make good thin broaches. but you still want a hole or 2 to get into and open up/slot to depth (that can be challenging if very thin)

 

[Pinoy Knife]

for the end mill try a 1.5 mm high speed bit in a Dremel router .. (since you don't have a milling machine)

 

[weo]

i think the First problem might be a small enough drill bit to start the slot

That's not a problem. Right now my smallest bit is 0.050, which is why I was looking for that sized end mill.

Thanks for the responses, everyone. The X-acto worked for this knife, and after a little research I found that this version of x-acto fine cut saw has a 0.012" kerf:
https://widgetsupply.com/product/beo16-30450.html