I wanted a metal blade instead of a printed one. First I was thinking about starting with a piece of 1/4" plate. Then I found an old Harbor Freight file that was broke off at about 6-1/2".
With some searching I found that files can be made into a usable knife. Some say to completely anneal, modify, then reheat treat. Others say that it can just be tempered. With it only tempered it will need to be ground to shape while taking care not to heat it too much. I chose to just temper it. I put it in a 400 degree oven for a couple of hours then let it cool off.
Using an angle grinder I ground the file to the rough shape. It's still going to take quite a bit of sanding to get it to the final shape.
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