Making integral knife

[alexmin]

I rough milled a full integral knife from 1/2" O1 steel.
Now I need to file all sharp edges(around bolster and butt) to make small inside radius instead of sharp corners. I used an end mill with small radius but it chipped so results are far from nice.

I am using a file with one "safe" side. As I found it's pretty hard to keep file straight, level and at 90 degrees to other side.

Is there anything I can do to make it easier other that practice, practice, practice.

 

[Chris Meyer]

Alex,
It wasn't clear to me from your post exactly what kind of mill you were using. Did you try a corner rounding mill? It would like something like the one shown below. You can get them from any number of places, but here's the link to Enco's selection. If that's what you already tried, I appologize for being dense.

 

[alexmin]

I need to finish inside corners. Not outside one.
Here is what I have -

.

 

[Shing]

You can use a ball end mill, they are quite cheap on ebay. You can also use a round file with a file guide, Koval and Sheffield knife supplies have them.

 

[David Wesner]

Hi alexmin, I would just dress a small ( 1/64 )-( 1/32 ) radius on one of your e-mills (2 fluter is easiest) and fuzz each wall untill you have established the rad you want on the inside corners. Also, this is one case where a "stress relieving" cycle prior to "hardening & tempering" would be one of the steps you'll not want to skip.