I am only modifying hardened factory blades, so I can't use files. Basically I grind a slot to the pivot hole with a 4 X 1/8" cut off wheel mounted in an angle head grinder which is clamped to a Work-Mate. The flat that allows the blade to be slid under the rocker tooth is ground on the slot wheel grinder. The picture won't upload. I will email it to you.
The slot wheel is rubber on top and ceramic underneath. The work is brought up under the wheel where a strong overwheel light lets you see the material being removed.
This tool is great for sharpening screwdriver blades, chisels, and gravers.
It's fun to play with materials, ideas, and custom designs. I tend to shy away from Carbon steel especially for food prep. The stainless steels don't lend themselves to forging or home heat treat. My latest acquisition has a CPM S-125-V blade (not a DIY project).
I have also made exchangers out Bucklites using #5X40TPI Helicoils. On such a conversion, no slot or flat (only the notch) is required. The blade is changed as in the 186 Titan by removing and replacing the pivot screw. In this setup, a skinny blade can be clamped using 2 appropriate washers. I also add pocket clips to Selectors and Bucklites using #2X56TPI Helicoils.
Bladesaver, Ergochef, and Messermeister all make various sized edge guards which can be used to transport your custom blades.
Congratulations on your one offs and for showing the rest of us how to take it up a notch.