You've told me that before and every time I'm tried that all I wind up doing is destroying the edge and having to clean up a pile of dirt. Do you have a tutorials or a video that shows the process or anything?
I take 180 grit wet and dry .. and attach it to a FLAT piece of pine..or an unused paint stir stick, something like that.. I also begin with a good quality snap-blade knife and a steel rule ( 1/8" thick) with a beveled edge, and cut the edge of the card at an angle.. 45 would be the perfect angle but that rarely happens..I aim for around 10-15 degrees to the inside of the joint.. that way when I glue up.. the outside edge has a razor sharp point +- and the inside gets filled with glue, and what ever I use to support the corners I will sometimes use magnetic 90s on the inside to get things right and square .. plus you can always glue up some 90 degree "L's" with a little waxed paper to stop glue from sticking to them for the outside.. anything that is heavy can be used to prop things up.. I have some 1/2" steel plate for steel bolts on metal girders I use ...the list can go on forever.but you get the Idea!
as far as machinist files.. you might look for them under the name of Swedish Files, as they are sometimes called that also..mainly as they usually come from Sweden for clockwork..or used to anyway.. that's where I got my 12 piece set from and why...also! Damn that was a long time ago..! You might want to see if you can find just a triangle, bladed flat and a round..that's about all you really use, I'll bet a full set of good ones are not cheap any more!
PS.. I forgot.. Keep a steady hand cutting the angle.. I see your using chip board..which is hard and a bit difficult to cut, dont wobble on the cut!
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