Rasps and Files Shape and Smooth More (And Sand Less) with These Simple Tools

Rasps and Files Shape and smooth more (and sand less) with these simple tools.

by Craig Bentzley

For years, I’ve regarded my tools because they’re quick and most other hand tools, files and rasps and files as my not-so-secret efficient to use. Whether the job rasps come ready to work fresh secret weapons. Hidden in plain calls for heavy stock removal, out of the package. The biggest sight beside my workbench, my erasing tool marks, refining hurdle to using these tools may collection has never generated a curves, taming tear-out, fitting be selecting the right ones. single comment from any visitor. a metal part, or even repairing Read on to learn what’s Admittedly, these simple steel- some other tool, there’s a file or available and how you can make toothed tools lack the romance of rasp that can get the job done. these toothy tools work for my planes, handsaws, and chisels, These simple shapers and you. As a wrap-up, I’ll provide but what they lack in allure, smoothers require a bit of skill you with a starter set that they make up for in function. to use effectively, but as you’ll can be put to immediate use Truth be told, files and rasps soon see, the learning curve is in almost every workshop. rank36 woodcraftmagazine.comamong my most reached-for Oct/Nov 2013surprisingly short. And unlike Rasps

General-purpose rasp ($10 - $15) Easily identified by their (In contrast, a dull rasp will prominent triangular teeth, skip across the workpiece.) rasps excel at initial shaping With rasps,Photo as with B other and sculpting operations on hand tools, you get what you wood. Unlike other shaping pay for (see , below). tools, such as drawknives Generic general-purpose and spokeshaves, rasps won’t wood rasps, sometimes tear out material where the referred to as “cabinet” grain changes direction or if rasps, have uniform Grobet Patt ernmaker’s rasp ($90) the stock is highly figured. rows of teeth that leave Using a rasp is fairly a fairly ragged surface intuitive, but a few tips can in their wake. The poor help you achieve faster cuts cut quality can require and smoother surfaces. When considerable clean-up. using a rasp, start by making Better quality a few light test strokes to rasps are labeled as determine the preferred angle “patternmaker’s” or of attack. (This is especially “cabinetmaker’s” rasps. Hand-sti tched Cabinetmaker’s rasp ($110) true with hand-stitched rasps. These tools sport Many are designed for right- staggered teeth that leave or left-hand use only.) Then, a much smoother surface use long, continuous passes than general-purpose at approximately a 45° angle, rasps. Patternmaker’s rasps simultaneouslyPhoto A feeding down can be machine-made or and across the work, as shown hand-stitched. As you might in . Let the tool do the expect, the priciest hand- work; a sharp rasp should not stitched rasps require the require much pressure to cut. least amount of clean-up.

B Bett er machine- and hand- A sti tched rasps cut quicker and Feed the rasp simultaneously down and across the work. produce smoother surfaces than Try to use the full length of the tool to wear the teeth evenly. a visibly coarser, low-cost rasp.

Story photos: Paul Anthony; Product photos: Larry Hamel-Lambert Oct/Nov 2013 woodcraftmagazine.com 37 Files for Working Wood

10" Half-Round Coarse Wood File Files are used to refine round files, I find the 8-inch and the rasped surfaces, but 10-inch long double-cut bastard they can also serve as files best for woodworking. stand-alone shaping tools. (Because the teeth on shorter, For most woodworking finer-cutting files quickly chores, I use fairly coarse clog with sawdust, I reserve files, like the ones shown them for metalworking.) at left. With most files, Files cut on the push stroke, tooth size is proportional but how you feed the tool to tool length; the longer across the work can influence the tool, the larger the the cutting speed and quality. teeth. I find the 6-inch Feeding the tool down and and 8-inch long round diagonally across the wood, as files are most useful done with a rasp, isPhoto suitable C for in the woodshop, as general shaping and fairing. For the 10-inch is a bit too rougher shaping ( ), you 6", 8" & 10" round fi les aggressive. When it can feed the file perpendicularly comes to flat and half- across the work, which is called “cross-filing.” For a smoother surface, run the file parallelPhoto D with the grain, called “draw- filing” ( ). Clean your teeth Tip Alert A fi le card is a must-have accessory. Use the nylon bristle side to clean rasps and the wire bristle side to clean fi les. You can use a metal To prevent prematurely dulling a pick or fi nishing nail to clean stubborn debris from fi le teeth, but any fi le, lift it on the return stroke. metal–even brass bristles–will eventually dull your rasp’s teeth.

C Cross-ﬁ ling removes stock quickly, but leaves a rough surface and may create D some chip-out at the back of the cut. Draw-ﬁ ling is slower, but produces a smoother surface.

38 woodcraftmagazine.com Oct/Nov 2013 Files for Working Metal Single-Cut

As we all know, woodworkers straightening and refining often work with metal as well critical metal surfaces. When as wood. Files can do double- I need to remove a lot of metal duty, but I find that once a file during initial rough shaping is used on metal, it doesn’t or fitting, I’ll start with a perform as well as on wood double-cut file and then Double-Cut anymore. For that reason, I follow up with a single-cut suggest investing in a separate file for the finished surface. set of files for metal work. In addition, there are three Metal files are available in two tooth sizes: bastard (coarsest), Tip Alert types of tooth configurations: second-cut, and smooth (finest). Aluminum and brass will quickly single-cut and double-cut (see You can shop around for shorter clog ﬁ le teeth. To make it easier photo at right). Single-cut files files with larger teeth, but in to remove built-up debris, try have a single set of parallel most stores, the in-stock files rubbing a piece of chalk across teeth. Double-cut files have a are sold in common-size tooth the surface of the ﬁ le before use. second, opposing set of teeth combinations. (See the “File and that create a diamond pattern. I Rasp Starter Set” page 39 for prefer using single-cut files for specific recommendations.) Metal Working for Woodworkers

Using a straight- ﬁ ling moti on quickly reestablishes a straight edge on a cabinet scraper.

Use a small round chainsaw ﬁ le to quickly shape curved A mill ﬁ le is suitable for metal parts, such as beading clean-up and general blades for a scratch stock. shaping, such as soft ening sharp edges and removing nicks from a plane sole.

Capable of ﬁ tti ng into ti ght spots, needle ﬁ les can be used to shape and smooth ragged edges, such as those on rough-cast hardware.

Oct/Nov 2013 woodcraftmagazine.com 39 Riﬄ ers

Rifflers are slim, double-ended To use a riffler, hold the tool tools curved to opposing shapes. like a pencil, apply pressure They are well-suited for getting with the finger of your other into tight areas and doing detail hand, and work in back-and- work or cleaning up carvings. forth strokes. Admittedly, riffler They are sold in a wide variety work can be tedious. Because of configurations, including the cutting face is small, the flat, round, half-round, and work goes slowly and the teeth triangular. (Rifflers are available clog quickly. However, for their with either file or rasp teeth. I ability to erase the tool marks prefer the files, as I find rasp- out of reach of larger tools, they rifflers a tad too aggressive.) earn their keep in my shop.

Riﬄ ers aren’t the fastest cutti ng tools, but they oﬀ er a precise way to clean up ragged edges in ti ght areas.

Iwasaki Files A fairly new entry into the world like miniature chip breakers. scarring them. These fi les haven’t of wood shaping tools, Iwasaki (They’re good for wood and yet bumped any tools from my fi les deserve special menti on. plasti c, but don’t even think must-have starter set, but they Although technically fi les, these of using them on metal.) are an att racti ve, aff ordable tools cut as aggressively as Iwasaki fi les are available opti on for woodworkers saving rasps, and sti ll produce super- in a wide range of sizes and up for a hand-sti tched rasp. smooth surfaces. The secret is confi gurati ons (see Woodcraft . in the cutti ng edges. The milled, com). All of the profi les have chemically etched teeth shear "safe" (tooth-free) edges, allowing materials, producing shavings them to work up against adjacent instead of dust. In additi on, the surfaces without diagonally-cut groove patt ern helps eject material before it clogs the teeth–working much

With sharp teeth that cut fast and leave a smooth surface, Iwasaki ﬁ les can serve as a single- tool stand-in for ﬁ les and rasps.

40 woodcraftmagazine.com Oct/Nov 2013 File and Rasp Starter Set

Protect Considering the diff erent sizes You can build a decent starter set yourself, and tooth confi gurati ons of fi les for about as much as you’ll pay and rasps, selecti ng a starter set for a single premium hand plane. and your tools for shaping and smoothing can be Here’s a list of my go-to tools. downright dizzying, but don’t fret. 1. Patt ernmaker’s rasp ($90) 1 A quality patt ernmaker’s rasp is an You’ll want to make or buy investment. Buy the best tool you can handles to protect your hands aff ord, take care of it, and it will tackle all from injury when handling these sorts of shaping and sculpti ng chores for years to come. Rasps are available in fl at, tools. Auxiliary handles are half-round, and round confi gurati ons. I fi nd sold for grasping the tool at its that a half-round rasp is the most useful. far end, but a wrap of masking 2 tape will also do the job. 2. 8" single-cut bastard To protect your rasps, files, round fi le ($5) and rifflers , store them in a rack Good for getti ng into ti ght radii and or tool roll to prevent the edges enlarging holes on woodworking from banging together. Rust can projects. Consider buying a second for 3 also contribute to premature metalworking chores, such as fi ling curved dulling. For long-term storage, scraper blades and fi tti ng hardware. consider using a sealed tool 3. 10" half-round coarse box with a VCI (vapor corrosion wood fi le ($25) inhibitor) inside. Oils and other Although typically used aft er initi al dust-collecting lubricants shaping with a patt ernmaker’s rasp, should not be used because this fi le can serve as a stand-alone 4 the teeth will load up more shaping tool for light-duty work. readily and require more frequent 4. 8" double-cut bastard cleaning. half-round fi le ($8) I oft en use this fi le to clean up surfaces aft er working on them with a 10" fi le, but it can also be used for general metal-shaping chores. 5 5. 10" single-cut bastard mill fi le ($8) Although this is my go-to tool for truing up edges on cabinet scrapers and performing other metalworking jobs, it is equally handy for a host of wood-shaping chores, so buy two.

3 6. ⁄32" diameter × 8"-long 6 chainsaw fi le ($5) This slim fi le is perfect for smaller metal- shaping chores, such as creati ng scratch stock and molding plane blades. It’s also handy for cleaning up the edges of metal hardware and machinery. 7 7. Needle fi le set ($25) These super-small fi les are indispensable for intricate shaping and clean-up of both metal and wood, including the smoothing of scroll-sawn edges.

Riﬄ er photos: Bob Ett er Oct/Nov 2013 woodcraftmagazine.com 41 SUBSCRIBE! 2 YEARS for $29.99!

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