I had to make a jig to go along with my K-Groove axles. Align two blocks of wood. Then drill alignment holes at each end the size of some scrap axles. Then use a Forstner bit and drill about 3/8 deep. Then use your axle bit and drill down the center. Then open the halves and install masking tape the width of your file in layers as shown. Then put it all together with an axle. Then install your file in the groove and file away with your grip over the axle head. In 30 seconds you'll have a sweet looking K-Groove. I already had these files but they are pricey. I saw some on ebay for just a few dollars and should do the trick. My file is .018 inch. Yours can be whatever you want? But I would suggest no more than about .025 inch wide. This was my first try and it works great. No need for that Dremel and disc! I'm sure there will be some really nice K-Groove Kutters from the fine world of car builders. Please post pictures of the ones you build.
