Fri Mar 23, 2012 5:38 pm by Aedalas
You're not going to notice 3 thousandths of an inch much at all. Also, sanding will take care of most of that anyways, if not all.
Without knowing what you're doing I can't offer much in the way of tips, but quenching is important.
Also, if you have a spare piece of 2x4 laying around I highly recommend making a bench pin. I wouldn't even attempt to make a pick without one now. With a Rai groove of course. If your bench and chair are the right height you don't even have to attach it, I pin mine between my leg and the underside of my bench and it works out great.
If you use a Dremel or grinder to shape it (quench!) finish using a flat file to make a nice straight edge.
Oh, and round files make a good start for a hook. Just file straight down then file away the shaft side with a flat file, the piece that is left is the inside curve of your hook already shaped for you.
As for sanding, go to at least 1000 grit in my opinion. 400 is "enough" but mirror finishes look better. I go to 2000 with mine.
Also on the subject of sanding, if you have an old sanding drum for a Dremel you can cut strips of 1000 grit sandpaper (or 400 or whatever) and superglue it to an old drum. Just make sure you pay attention to the Dremels rotation when you make your overlap.
"What if you people made giant boulders illegal because of all the innocent people who get killed by giant boulders?"
"People dont kill people with giant boulders"
"They will if you take away their assault rifles"