Perfect Your Wood Shaping With the Best Mill Files

Buyer’s Guide to Finding a Mill File

Why Should You Buy Mill Files?

A mill file is a must-have tool if you’re a passionate DIYer or professional. These versatile tools are great for metal and woodworking projects, helping improve both the performance of other tools and the entire project itself.

Typically, in metalwork, you rub a mill file against the blade of other tools, sharpening them. This is necessary for driving clean and accurate results. However, there are various other uses for mill files in woodworking.

These tools help scrape off any unwanted material and are highly useful if you make a mistake in a project and want to correct it. There are limitations, though, like you can’t really reverse a deep cut by scraping it away.

Mill files are also useful for shaping and trimming wooden pieces. You can use them for creating perfect square blocks and neat edges. They’re also great tools for smoothing and flattening rough surfaces, though it will take longer than with a dedicated tool like a jack plane.

Apart from their versatile functionality, mill files are a must-have tool because of their simple and lightweight design, they don’t occupy a lot of space and are extremely portable. These products are also available at affordable prices, making purchasing them an easy choice as well as a good investment.

Mill Files vs Flat Files

Often, people get confused between mill files and flat files. While they may sound similar, they are two different tools. Here is a detailed comparison:

Mill files refer to draw filing tools combining a large metallic blade with a handle. Their purpose is to sharpen other blades and shape wood. They can also be used for trimming, flattening, and downsizing.

Flat files are a type of mill file designed for working with flat surfaces. They have a rectangular, long blade that may or may not be double-cut. Except for this structural difference, you can use it to fulfill all the same functions as a mill file.

Since mill files come in several different types (based on shape), it’s not right to use these terms interchangeably. It’s especially important if you’re a woodworking professional.

Factors To Consider When Buying Mill Files

Mill files are undoubtedly worthy investments for woodworking projects. However, not all mill files will be ideal for your specific needs.

This is why you should evaluate a product thoroughly before purchasing it. Here are some factors for ensuring the file you choose is the right tool for you.

Mill file shape

The hardened blade of a mill file can come in a lot of different shapes, including square, flat, round, half-round, triangle, pointed, and more. You need to select a shape according to the project you have in mind.

For example, round mill files work best for making round openings larger. Meanwhile, triangle mill files work on corners and edges perfectly. And, they can also sharpen various styles of blade teeth.

Teeth

Since it affects performance, a mill file’s teeth hold a great deal of importance. Evaluate the following two sub-factors to ensure unbeatable results.

Configuration

The teeth configuration is its pattern or design. Although there are plenty of new versions available, the two classic configurations are single-cut and double-cut. Here’s the difference between both:

• Single-cut files feature teeth designed for cutting in one direction, 65 degrees in most models. These files also deliver the smoothest results
• Double-cut files feature teeth in a crisscross design. They are cut at opposing angles, making them sharper. And, you can use them for filing material faster, though the results will be rougher
• Some specialty cuts include shear cut, vixen cut, and maxi-sharp cut, these are hybrid versions for performing specific tasks

Number of teeth

The number of teeth determines the mill file’s relative sharpness. Keep in mind that fewer teeth result in coarser filing, whereas more teeth result in smoother. Ideally, you will come across five grades depending on the number of teeth.

• Dead Smooth (100 TPI)
• Smooth (60 TPI)
• Second-cut (36 TPI)
• Bastard-cut (26 TPI)
• Rough (16 TPI)

Please note we have listed them in smooth to rough order. A smooth mill file will provide neater and cleaner results than a rougher version.

Size

A mill file’s size has a great impact on its versatility. You can use large mill files for covering bigger areas on wooden panels and blades. However, you cannot use them for precision-based tasks like trimming edges or sharpening small blades.

Build quality

Mill files always feature metallic blades. However, the type of metal used in the blade can affect its longevity. Typically, hardened carbon steel is the best option.

It’s a powerful metal capable of resisting all kinds of damage. You can subject it to a great deal of pressure and force without worrying about a single crack. These mill files can also remain rust-free for years. Besides the blade, consider the material of the handle too. Mostly, the handle is an extension of the blade, making it equally durable. If it’s not, opt for high-quality hardwood or plastic fixed into the blade with steel screws.

These material specifications will help ensure a handle is both unshakeable and unbreakable, letting you use it as roughly as you like.

Ergonomics

The handle also determines comfort level. It should be thinner than the blade, making handling easy. Also, it should have a curved and angled design for promoting a firm grip.

You definitely don’t want a mill file slipping from your hands, it can pose a serious safety hazard. Look for grooves and textured surfaces, ensuring better control over the tool.

Safety edge

At times, woodworking projects require trimming or shaping only one of the adjacent sides. In these cases, a mill file should possess a safety edge. A safety edge refers to the smooth, flat side of a mill file.

It helps protect the side that doesn’t require filling. So, if you work on these kinds of tricky projects, make sure the selected product comes with a safety edge.

Using a Mill File Properly

Using a mill file is a fairly simple and straightforward task. Begin, using your dominant hand, for most people this will be their right. Remember, woodworking is an activity requiring a high degree of dexterity, so proper control remains vital.

Place your other hand on the tip of the mill file. Use this hand for pressing the tool against the surface and your dominant hand for guiding the direction. Rub the mill file several times to achieve the desired results.